Free dump truck / ADT 500-hour service procedure

• The MapTrack dump truck / ADT 500-hour service procedure contains 14 checks across 8 sections. Sections covered: Engine (additional to 250-hour), Transmission and Driveline (additional to 250-hour), Hydraulic System (additional to 250-hour), Brakes (additional to 250-hour), Suspension and Steering (additional to 250-hour), Dump Body (additional to 250-hour), Wheels and Chassis (additional to 250-hour), Cab (additional to 250-hour).
• Engine: replace fuel filters (primary and secondary), replace air filter (outer element), check fan belt condition and tension.
• Transmission and driveline: drain and replace transmission oil and filter.
• Hydraulic system: replace hydraulic return filter, take hydraulic oil sample for analysis.

Learn more about maintenance and work orders in MapTrack.

• Reduced breakdowns: regular filter changes and transmission servicing prevent failures that cause unplanned downtime on haul roads.
• Extended component life: replacing hydraulic and transmission filters at the correct interval protects pumps, valves and clutch packs from contamination damage.
• Lower repair costs: catching brake wear, steering play or dump body cylinder leaks at 500 hours prevents expensive emergency repairs.
• Operator safety: full brake inspection, steering checks and dump body integrity assessment at the 500-hour interval protect operators and site personnel.
• Compliance: documented service records demonstrate that equipment is maintained to WHS standards, supporting insurance and regulatory obligations.
• Resale value: a complete service history increases the machine's value at trade-in or auction.

• Engine: replace fuel filters (primary and secondary), replace air filter (outer element), check fan belt condition and tension.
• Transmission and driveline: drain and replace transmission oil and filter.
• Hydraulic system: replace hydraulic return filter, take hydraulic oil sample for analysis.
• Brakes: full brake inspection with pad/shoe thickness measurement on all axles.
• Suspension and steering: inspect suspension bushes, pins and dampers; inspect steering ball joints, tie rods and drag link.
• Dump body: inspect dump body cylinders (seals, rod condition), inspect body pivot pins and bushes (measure play).
• Wheels and chassis: torque wheel nuts all positions, inspect chassis for cracks; service A/C system.

1. Complete the full 250-hour service procedure first. This includes engine oil and filter, grease points, fluid level checks, dump body inspection and all basic inspections.

   Use the 250-hour checklist as a reference to ensure no items are missed. Confirm all 250-hour defects have been addressed or recorded before proceeding to the 500-hour tasks.

2. Record the equipment details and current hour meter reading at the top of the 500-hour service procedure form.

   Include the machine serial number, fleet ID, make, model and site location. Cross-check the hour meter reading against the last service to verify the interval is correct.

3. Replace the fuel filters (primary and secondary), replace the outer air filter element, and check the fan belt condition and tension.

   Prime the fuel system after fitting new filters to avoid air locks. Inspect the outer air filter element for damage before discarding. Check belt deflection against the manufacturer specification, typically 10 to 15 mm at the midpoint.

4. Drain and replace the transmission oil and filter. Record the oil condition on the form.

   Use the correct ATF or TO-4 fluid as specified by the manufacturer. Note the colour and smell of the drained oil, as dark or burnt fluid can indicate clutch pack wear. Refill to the correct dipstick mark and check level again after a short run.

5. Replace the hydraulic return filter. Take a hydraulic oil sample for laboratory analysis and label it with the machine details.

   Collect the sample from the return line while the system is at operating temperature, using a clean sample bottle. Label with fleet ID, date, hours and sample point. Send to an accredited laboratory for particle count, viscosity and wear metal analysis.

6. Perform a full brake inspection: measure pad or shoe thickness on all axles and record measurements on the form.

   Use a vernier calliper or brake gauge to measure pad thickness. Compare readings against the manufacturer minimum specification. Inspect discs or drums for scoring, heat cracks or run-out. Flag any components at or near minimum thickness for replacement.

7. Inspect suspension components (bushes, pins, dampers) and steering components (ball joints, tie rods, drag link).

   Check for visible play, cracking, deformation or oil leaks on each damper. Use a pry bar to test bush and ball joint play where safe to do so. Record any excessive movement and compare to manufacturer tolerances.

8. Inspect dump body cylinders for seal leaks and rod condition. Inspect body pivot pins and bushes and measure play.

   Extend the dump body fully and check each cylinder rod for scoring, pitting or chrome peeling. Measure pivot pin and bush play with a dial indicator and compare to the manufacturer limit, typically 1 to 2 mm maximum.

9. Torque wheel nuts at all positions. Inspect the chassis for cracks or damage. Service the A/C system.

   Use a calibrated torque wrench set to the manufacturer specification, typically 600 to 800 Nm for ADTs. Inspect the chassis around high-stress areas such as articulation joints, tow pin mounts and body pivot brackets. Check A/C refrigerant pressure and cabin filter condition.

10. Start the engine and check for leaks, abnormal noises or warning lights. Record any defects in the notes section.

    Run the engine to operating temperature and cycle the dump body, steering and brakes. Walk around the machine checking for new fluid leaks. Confirm all instrument readings are within the normal range before signing off.

11. Set the next service due hours (next 500-hour and next 1,000-hour intervals). Sign off and update the maintenance log.

    Calculate the next service hours by adding 500 and 1,000 to the current reading. Record the due hours on the service sticker inside the cab and in the fleet management system. Ensure the technician name and licence or trade number are captured.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• WHS Act 2011
• WHS Regulations 2011 Chapter 5
• AS 4024 (Safety of Machinery)
• NHVR Maintenance Management System

• Model WHS Regulations (Safe Work Australia)
• Model Work Health and Safety Act (Safe Work Australia)
• Heavy Vehicle National Law and Regulations (NHVR)
• AS 4024 series, Safety of machinery (Standards Australia listing)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

• Dump truck 250-hour service procedure
• Truck / heavy vehicle pre-start checklist
• Heavy equipment maintenance checklist
• Maintenance scheduling
• Asset tracking
• Plant compliance
• Construction industry
• Mining industry