Free dump truck / adt 250-hour service procedure
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Free dump truck 250-hour service checklist (PDF-ready). Engine oil, filters, differentials, dump body, driveline grease and tyres. Download free.
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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:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Trigger work orders automatically when a fault is logged during an inspection.
- 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. Each submission is stored as a timestamped PDF against the asset record.
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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.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- WHS Act 2011 (Section 19 - Primary duty of care)
- WHS Regulations 2011, Chapter 5 - Plant and Structures (PCBU duties for maintenance and inspection of mobile plant)
- ISO 6165 (Earth-moving machinery)
- Safe Work Australia Code of Practice: Managing Risks of Plant in the Workplace
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