Free dump truck / ADT 250-hour service procedure
Free dump truck 250-hour service checklist (printable 23-point PDF). Engine oil, filters, differentials, dump body, grease and tyres. Download free.
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Updated 26 Oct 2026
Dump Truck / ADT 250-Hour Service Procedure
Minor service - articulated dump truck and rigid dump truck (all makes)
Engine
Transmission and Driveline
Hydraulic System
Steering and Suspension
Tyres
Dump Body
Electrical and Safety
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Short answer
A dump truck 250-hour service checklist records the minor service on an articulated or rigid dump truck: engine oil and filter, fuel water separator, fluid levels, greasing, tyres, dump body structure, hydraulics, brakes and safety devices. Fitters complete it every 250 engine hours under the manufacturer's schedule. Regulation 213 of the model WHS Regulations requires plant maintenance by a competent person following the manufacturer's recommendations.
Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack dump truck / ADT 250-hour service procedure contains 23 checks across 7 sections. Sections covered: Engine, Transmission and Driveline, Hydraulic System, Steering and Suspension, Tyres, Dump Body, Electrical and Safety.
- It falls every 250 engine hours: about every four to six weeks in steady use, or every two to three weeks where trucks run continuously in mines and quarries.
- This is a maintenance job for a qualified mechanic or fitter, not the operator's daily check: fluids are drained and replaced, filters changed and every grease point done.
- Lower the body fully for routine work, and if work must be done under a raised body, fit the body prop first so the hoist is not the only support.
- Grease each driveline universal joint until fresh grease purges from all four trunnion seals, and count grease points against the manufacturer's chart so none are missed.
- Check the body for cracks at welds and corners, and measure floor thickness in the loading zone so wear plates are replaced at a planned shutdown.
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What is a dump truck / ADT 250-hour service procedure?
A dump truck 250-hour service checklist is a structured maintenance procedure used to perform the first tier of scheduled preventive maintenance on an articulated dump truck (ADT) or rigid dump truck. It is performed every 250 engine hours, which equates to approximately every four to six weeks of full-time operation, and is classified as a minor service. The procedure covers engine oil and filter replacement, air filter inspection, fuel system maintenance, transmission and differential oil level checks, hydraulic system checks for the dump body, driveline greasing, steering and suspension grease points, tyre inspection, dump body structural inspection, electrical system checks and safety device testing. Unlike a daily pre-start check (which confirms the machine is safe to operate), the 250-hour service involves actual maintenance actions: draining and replacing fluids, replacing filters, greasing components and inspecting for wear. It is typically performed by a qualified mechanic or fitter, not the operator.
Maintaining a disciplined 250-hour service schedule is critical for dump trucks operating on haul roads, quarries and construction sites where dust, impact loading and vibration accelerate component wear. Under the WHS Act 2011 (Section 19), the person conducting a business or undertaking (PCBU) has a primary duty of care to ensure that plant is maintained so it remains safe for use. Skipping or delaying 250-hour services leads to accelerated engine wear from contaminated oil, increased risk of driveline or differential failure, undetected dump body cracking and degraded braking performance. Each of these failures can result in unplanned downtime costing thousands of dollars per shift, or worse, a serious safety incident on an active haul road. A completed checklist also provides the documented maintenance record needed for WHS audits, insurance renewals and equipment resale.
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Benefits of using this dump truck / ADT 250-hour service procedure
- Reduced breakdowns: regular oil, filter and fluid changes prevent engine, transmission and differential failures that cause unplanned downtime on site.
- Extended component life: clean oil and correct lubrication reduce wear on engine, transmission, differentials, dump body hydraulics and driveline universal joints.
- Lower repair costs: a 250-hour service costs a fraction of an emergency breakdown repair. Catching issues early prevents cascading damage.
- Operator safety: inspecting safety devices, brakes, tyres, dump body integrity and hydraulic hoses 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 and 500-hour services increases the machine's value at trade-in or auction.
Benefits of digitising forms in MapTrack
When you digitise dump truck service procedures in MapTrack, you get:
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- Build conditional logic (show or hide questions based on answers).
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- Set who can view, fill in or edit forms with user roles.
- Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
- Raise a work order from a submitted form with an automation you set up.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
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What to include in a dump truck / ADT 250-hour service procedure
This dump truck / ADT 250-hour service procedure covers 7 key areas:
- Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant, inspect exhaust/DPF, check AdBlue/DEF.
- Transmission and driveline: check transmission oil level, check differential oil levels (front, centre, rear), grease driveline universal joints.
- Hydraulic system: check hydraulic oil level (dump body system).
- Steering and suspension: grease king pins and steer axle, grease articulation joint (ADT), grease suspension pins.
- Tyres: check tyre pressures all positions, inspect tyre condition and tread.
- Dump body: inspect body for cracks, wear plates and floor thickness, check tailgate mechanism and latches, inspect dump cylinder pins and bushes.
- Electrical and safety: check battery, test lights, horn, reversing alarm, camera, check seatbelt, ROPS and fire extinguisher.
How to use this dump truck / ADT 250-hour service procedure
- Park the dump truck on level ground, lower the dump body fully, apply the park brake and shut down the engine. Allow the engine to cool before draining oil.: Position on a firm, level surface in the workshop or service bay. Lower the dump body completely and engage the body prop safety lock if performing work underneath. Apply the park brake and chock wheels. Allow at least 15 minutes for the engine to cool.
- Record the equipment details and current hour meter reading at the top of the service procedure form.: Capture the fleet number, make, model, payload capacity, body type (articulated or rigid) and the current engine hour meter reading. Compare against the previous service to confirm the correct 250-hour interval has elapsed.
- Start with the engine section: drain the old engine oil, replace the oil filter, fill with new oil to the correct level, then inspect the air filter, drain the fuel/water separator and check coolant.: Use 15W-40 CI-4 or CK-4 diesel engine oil. Typical capacity is 25-45 litres depending on machine size. Check the air filter restriction indicator and replace the element if in the red zone. Drain the fuel/water separator bowl completely. Check coolant level and inspect hoses for cracking.
- Check transmission oil level, check all differential oil levels (front, centre and rear), and grease driveline universal joints.: Check transmission oil on the dipstick at operating temperature (typically with the engine running in neutral). Check front, centre and rear differential oil through the level plugs. Grease each driveline universal joint with EP2 grease until fresh grease purges from all four trunnion seals.
- Check hydraulic oil level for the dump body system. Grease king pins, steer axle, articulation joint (ADT) and suspension pins.: Check the dump body hydraulic oil level on the sight glass with the body fully lowered. Apply EP2 grease to king pins, steer axle pivots, the articulation joint (on ADTs), and all suspension pin points. Count grease points against the manufacturer chart to ensure none are missed.
- Check tyre pressures at all positions and inspect tyre condition and tread depth.: Use a calibrated tyre gauge and inflate to the cold pressure specified by the manufacturer (dump truck tyres typically 450-700 kPa depending on size and load). Inspect each tyre for cuts, bulges, sidewall damage and embedded objects. Measure tread depth and flag any tyre below the minimum depth for replacement.
- Inspect the dump body for cracks, check wear plates and floor thickness, check the tailgate mechanism and latches, and inspect dump cylinder pins and bushes.: Inspect the dump body at welds, corners and high-stress areas for cracking. Check wear plate condition and floor thickness, particularly in the loading zone. Test tailgate latches and hinges for correct operation. Inspect dump cylinder mounting pins and bushes for wear, play or seal leaks.
- Check the battery, test all lights, horn, reversing alarm and camera. Check the seatbelt, ROPS and fire extinguisher.: Inspect battery terminals for corrosion and ensure connections are tight. Test all exterior lights, horn, reversing alarm and the reversing camera display. Inspect the seatbelt webbing and buckle. Visually check the ROPS structure for damage. Confirm the fire extinguisher gauge is in the green zone and the expiry date is current.
- Start the engine and check for leaks, abnormal noises or warning lights. Check all instrument readings. Record any defects or recommendations in the notes section.: Run the engine for five minutes and monitor oil pressure, coolant temperature, transmission temperature and hydraulic temperature. Walk around the machine checking for fluid leaks. Operate the dump body through a full raise and lower cycle to check for smooth operation and cylinder leaks. Record all defects.
- Set the next service due hours (next 250-hour and next 500-hour intervals). Sign off and update the machine's maintenance log.: Calculate the next 250-hour and 500-hour service due hours from the current reading. Update the service sticker in the cab, the machine maintenance log and the fleet management system. Obtain sign-off from the service technician.
In MapTrack, you can schedule and track maintenance digitally, by date or meter reading. Each submission is stored as a timestamped PDF against the asset record.
Get the free templateEnter your email above to download the full dump truck / ADT 250-hour service procedure as a PDF.Back to download formHow often should you complete this service procedure?
Dump trucks should receive a 250-hour minor service every 250 engine hours, which equates to roughly every four to six weeks of full-time operation on haul roads. Dump trucks accumulate hours quickly in mine and quarry environments where they run continuously, so the interval can be reached in as little as two to three weeks.
Between scheduled services, the operator must complete a daily pre-start inspection before each shift covering fluid levels, tyres, lights, brakes, dump body condition and safety devices. The 500-hour intermediate service adds filter replacements, transmission oil change, full brake inspection, steering and suspension checks, dump body cylinder inspection and hydraulic oil sampling. Always refer to the truck manufacturer service schedule for your specific model and operating conditions.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Model Work Health and Safety RegulationsMaintenance, inspection and testing by a competent person, following the manufacturer's or a competent person's recommendations. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Model Code of Practice: Managing risks of plant in the workplaceMaintaining plant to the manufacturer's instructions, and isolating energy sources before maintenance. | November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024) |
| Safe Work Australia |
| Model Work Health and Safety Act (Model Work Health and Safety Bill)Primary duty to provide and maintain safe plant, so far as is reasonably practicable. | Model WHS Bill as at 5 December 2025 (includes the Model WHS Legislation Amendment (Incident Notification) 2025) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
| Earth-moving machinery - Basic types - Identification and vocabularyDefines the basic earth-moving machine families and terms. Terminology only, not a service schedule. | ISO 6165:2022 (Edition 7) |
| International Organization for Standardization (ISO)Sold by the publisher |
Model Work Health and Safety Regulations
Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)
Maintenance, inspection and testing by a competent person, following the manufacturer's or a competent person's recommendations.
- reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
- Part 5.1: General duties for plant and structures for designers, manufacturers, importers, suppliers, installers and those managing or controlling plant.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Model Code of Practice: Managing risks of plant in the workplace
Edition: November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024)
Maintaining plant to the manufacturer's instructions, and isolating energy sources before maintenance.
- Section 3.6: Maintenance, repair and cleaning of plant, following manufacturer instructions and by competent people.
- Section 4.5: Isolating energy sources before maintenance, repair or cleaning, with lock-out as the most effective isolation procedure.
Model Work Health and Safety Act (Model Work Health and Safety Bill)
Edition: Model WHS Bill as at 5 December 2025 (includes the Model WHS Legislation Amendment (Incident Notification) 2025)
Primary duty to provide and maintain safe plant, so far as is reasonably practicable.
- s 19: Primary duty of care: a PCBU must ensure, so far as is reasonably practicable, the health and safety of workers and others, including safe plant, systems, training and supervision.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Earth-moving machinery - Basic types - Identification and vocabulary
Edition: ISO 6165:2022 (Edition 7)
Defines the basic earth-moving machine families and terms. Terminology only, not a service schedule.
- 3.2: Machine families: the basic types of earth-moving machinery and their terms.
International Organization for Standardization (ISO)Sold by the publisher
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Dump truck / ADT 250-hour service procedure</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Engine: drain and replace engine oil (15W-40), replace oil filter, inspect air filter, drain fuel/water separator, check coolant, inspect exhaust/DPF, check AdBlue/DEF.</li>
<li style="margin:4px 0;">Transmission and driveline: check transmission oil level, check differential oil levels (front, centre, rear), grease driveline universal joints.</li>
<li style="margin:4px 0;">Hydraulic system: check hydraulic oil level (dump body system).</li>
<li style="margin:4px 0;">Steering and suspension: grease king pins and steer axle, grease articulation joint (ADT), grease suspension pins.</li>
<li style="margin:4px 0;">Tyres: check tyre pressures all positions, inspect tyre condition and tread.</li>
<li style="margin:4px 0;">Dump body: inspect body for cracks, wear plates and floor thickness, check tailgate mechanism and latches, inspect dump cylinder pins and bushes.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/dump-truck-250-hour-service" style="color:#071D49;font-weight:600;text-decoration:none;">Dump truck / ADT 250-hour service procedure</a> by MapTrack</p>
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The MapTrack dump truck / ADT 250-hour service procedure contains 23 checks across 7 sections.
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