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Free dump truck monthly inspection checklist

Free rigid dump truck monthly inspection checklist. Chassis welds, dump-body pivot, hoist seals, hub planetaries, retarder, tyres + rims.

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Updated 26 Oct 2026

Dump Truck Monthly Inspection

Monthly periodic inspection

Your logo here
0 of 36 checks

Chassis & structural welds

1Chassis frame rail weld visual front to rear
2Front cross-member weld and bolt integrity
3Rear axle housing weld and mounting check
4Dump-body pivot pin and trunnion weld
5Hoist cylinder mounting trunnion weld
6Cab-frame and ROPS structural welds

Hydraulic hoses & hoist circuit

7Hoist cylinder rod surface and seal weep
8Hydraulic supply hose to hoist circuit
9Brake hose chafing under chassis
10Retarder cooling circuit hose condition
11Hydraulic tank breather and water trap
12Visible oil weep at fittings and seals

Final drives & suspension

13Hub planetary oil level at each driven wheel
14Final-drive leak check at each hub
15Suspension cylinder seal weep front and rear
16Suspension cylinder gas-charge reading
17Tyre tread depth and sidewall condition
18Rim crack, lock-ring and valve check per AS 4457.1

Brakes & retarder

19Service brake disc thickness measurement at each wheel
20Retarder function test on measured grade under load
21Parking brake hold-on-grade test
22Emergency brake response test
23Steering response under load

ROPS/FOPS & cab

24ROPS certification sticker present and legible
25FOPS certification sticker present and legible
26Cab mounting bolt torque check
27Seat belt condition and anchorage
28Fire suppression service tag in date

Body lift function test

29Full bed lift cycle with representative load
30Hoist cylinder behaviour and hydraulic pressure
31Bed pivot and rest contact on return
32No abnormal smoke, noise or hydraulic loss

Defects & close-out

33Defects photographed and logged
34Work orders raised for each defect with priority
35Competent person signature and date
36Next monthly inspection scheduled

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Maintenance and work orders →Best CMMS software →MapTrack vs MaintainX →

Short answer

A dump truck monthly inspection checklist records a competent person's examination of a rigid haul truck: structural welds, body pivot pins, hoist cylinders, final drives, brake discs, retarder, suspension cylinders, tyres and rims. Fitters complete it each calendar month as site practice, alongside OEM service intervals. Regulation 213 of the model WHS Regulations requires inspection by a competent person following manufacturer 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 monthly inspection checklist contains 36 checks across 7 sections. Sections covered: Chassis & structural welds, Hydraulic hoses & hoist circuit, Final drives & suspension, Brakes & retarder, ROPS/FOPS & cab, Body lift function test, Defects & close-out.
  • The monthly interval is site practice; regulation 213 points to the manufacturer's or a competent person's recommendations.
  • Check off-the-road rims and tyres against AS 4457.1 and AS 4457.2 (2024) and the rim manufacturer's instructions.
  • On NSW mines that need a mechanical engineering control plan, the plan sets plant inspection, testing and defect controls (Sch 2, s 2).
  • Run an out-of-cycle inspection after any reported retarder loss, brake imbalance, suspension sag or suspected crack, and park the truck until repaired.

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Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a dump truck monthly inspection checklist?

A dump truck monthly inspection is a structured form used by maintenance supervisors and competent persons to verify that a rigid mining or quarry haul truck is mechanically sound, structurally intact and safe to continue running production cycles between major services. Rigid dump trucks such as the CAT 770, 777 and 789, Komatsu HD-series and Liebherr T-series carry millions of tonnes per year over their service life, and the combination of payload, frame loading, brake system complexity and the cost of tyres and rims makes the monthly inspection one of the most evidence-heavy intervals in any heavy mobile fleet. A monthly inspection typically takes two to four hours per truck, is completed by a heavy-duty fitter, mechanical supervisor or other competent person (on a NSW mine that needs a mechanical engineering control plan, one with the competency the plan requires), and is signed off as evidence that every structural weld, pivot pin, hoist seal, hub planetary, brake disc, retarder, suspension cylinder, tyre and rim has been inspected against the OEM reject criteria.

The most evidence-heavy interval for rigid dump trucks is the monthly inspection, because it is where structural frame welds (chassis, front cross-member, rear axle housing), bed (dump-body) pivot pin play, hoist cylinder seal weep, hub planetary final-drive condition, brake disc thickness, retarder function, suspension cylinder seal and tyre and rim integrity are all measured and recorded in a single sitting. The largest consumable cost on the truck is tyres and rims, and the largest single capital risk is uncontrolled descent from brake or retarder failure on a loaded ramp, so both areas are checked formally rather than relying on the operator pre-start. The completed form is a signed and dated record of each inspection that helps show it was carried out by a competent person, as regulation 213 of the WHS Regulations 2011 (Part 5.1) requires. On NSW mines, the Resources Regulator guideline MDG 15 (Mobile and transportable plant for use on mines and petroleum sites) is also relevant, including its section on wheels, rims and tyres.

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Benefits of using this dump truck monthly inspection checklist

  • Catch chassis and axle-housing cracks: A monthly weld walk on the chassis, front cross-member and rear axle housing finds fatigue cracks early, well before a structural failure under load.
  • Protect the bed and hoist system: Dump-body pivot pin play, hoist cylinder seal weep and bed-wear measurements are recorded so production downtime is planned rather than forced.
  • Measure brake disc thickness: Service brake disc thickness is measured against the OEM minimum so the planner can stage brake-pack replacement during a planned outage rather than after a runaway.
  • Verify retarder function under load: Retarder system function is tested formally so the loaded descent capability is confirmed rather than assumed at the point of need.
  • Manage tyre and rim integrity: Tyre and rim are the most expensive consumable on the truck, and the form records monthly tread depth, sidewall condition and rim crack, lock-ring and valve checks.
  • Drive defect-to-work-order accountability: Every defect found during the monthly inspection is photographed, prioritised and converted into a maintenance work order so nothing lives unresolved on a paper form.

Benefits of digitising forms in MapTrack

When you digitise dump truck checklists 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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Saunders International

Steve McAllister

Asset Coordinator, Saunders International

What to include in a dump truck monthly inspection checklist

This dump truck monthly inspection checklist covers 15 key areas:

  • Chassis and front cross-member structural weld visual
  • Rear axle housing weld and mounting integrity
  • Dump-body (bed) pivot pin and bush play measurement
  • Bed liner wear and structural cross-member condition
  • Hoist cylinder rod, seal weep and mounting trunnion
  • Hub planetary final drive oil level and leak check
  • Service brake disc thickness measurement at each wheel
  • Retarder system function test under load
  • Suspension cylinder seal weep and gas charge verification
  • Tyre wear, tread depth and sidewall condition
  • Rim integrity (cracks, lock-ring seat, valve hardware) per AS 4457.1 and the rim manufacturer instructions
  • ROPS and FOPS certification sticker and cab-mount check
  • Hydraulic and brake hose chafing walk
  • Defect log review against last month plus open work orders
  • Function test of full bed lift cycle with representative load

How to use this dump truck monthly inspection checklist

  1. Plan and isolate.: Pull the truck out of the production cycle, park it on level ground, lower the bed onto its rest blocks and complete lockout-tagout on the master isolator, batteries and accumulator pressure. Wash down the chassis so weld inspection is meaningful, then review the hour meter, last service and any open defects so the inspection is informed by known issues.
  2. Inspect the chassis and axle housing.: Walk the chassis from front to rear with a torch, examining welds at the front cross-member, the engine mounts, the rear suspension towers and the rear axle housing. Look for paint cracks, rust streaks, fretting or any indication of fatigue, and mark any suspect weld for dye-penetrant testing. Confirm chassis frame rails are straight and undamaged.
  3. Check bed pivot, liner and hoist trunnions.: With the bed safely supported, measure dump-body pivot pin play, inspect bed liner wear at the front bulkhead and across the floor, and check the structural cross-members under the bed for cracking. Inspect the hoist cylinder rod surface, mounting trunnions and any visible seal weep on the cylinder gland.
  4. Inspect hub planetaries and final drives.: At each driven wheel, check the hub planetary oil level via the sight glass, look for leaks at the planetary cover and final-drive seal, and listen for abnormal noise as the wheel is rotated under controlled conditions. Record any low oil, contamination or visible metal in the oil sample.
  5. Measure brake discs and test the retarder.: Measure service brake disc thickness at each wheel against the OEM minimum and record the reading. Test the retarder system function on a measured grade with a representative load, confirming that the retarder holds the truck within the OEM expected deceleration curve. Confirm parking brake hold and emergency brake response.
  6. Inspect tyres, rims and suspension cylinders.: Measure tread depth at multiple points on each tyre, inspect sidewalls for cuts, separation and impact damage, and check each rim for cracks, lock-ring seat condition and valve hardware integrity, following AS 4457.1 and the rim manufacturer instructions. Inspect each suspension cylinder for seal weep, mounting condition and a gas-charge reading where measurable.
  7. ROPS, FOPS and hydraulic walk.: Confirm ROPS and FOPS certification stickers are present and legible, check cab mounting bolts and verify no unauthorised welding has been done to the cab structure. Walk every hydraulic and brake hose under the chassis and around the bed pivot, looking for chafing, oil weep and loose clamps.
  8. Function test the bed lift cycle.: With the truck warmed up on level ground, run a full bed lift cycle with a representative load on the bed if possible, watching for hoist cylinder behaviour, hydraulic pressure, abnormal noise and bed pivot response. Lower the bed back to rest and confirm smooth return.
  9. Document, sign and raise work orders.: Photograph every defect, record measurements against the form fields, sign the form as the competent person and convert each defect into a prioritised work order in the maintenance system. Schedule the next monthly inspection date and confirm no overdue work orders carry past 30 days.

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How often should you complete this checklist?

A rigid dump truck monthly inspection is conducted every calendar month for any haul truck in active mining or quarry production, alongside the OEM 250 and 500 hour service intervals and any major scheduled mid-life overhauls. Operations running long downhill loaded hauls, hot tyre conditions or high-payload application often shorten the interval to every 200 operating hours because brake disc, retarder, suspension and tyre wear all accelerate. Escalate to a quarterly or annual structural inspection after any rollover, runaway incident, brake-pack replacement, bed repair or contact with overhead services. Trigger an immediate out-of-cycle inspection if the operator reports retarder loss, brake imbalance, abnormal bed behaviour, suspension sag, tyre damage or any suspected structural crack. MapTrack schedules the monthly inspection against each haul truck, alerts the planner before it falls due, and converts every captured defect into a tracked work order with photo evidence.

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Frequently asked questions

A rigid dump truck monthly inspection covers structural weld visuals on the chassis, front cross-member and rear axle housing, dump-body pivot pin and liner wear, hoist cylinder seal and trunnion checks, hub planetary final-drive oil and leak status, service brake disc thickness measurement at each wheel, retarder function testing under load, suspension cylinder seal and gas-charge checks, tyre and rim integrity per AS 4457.1 and AS 4457.2, ROPS and FOPS sticker checks, a full hydraulic and brake hose walk, and a function test of the full bed lift cycle. Every defect is photographed and converted into a prioritised work order.

A daily pre-start on a rigid dump truck is a short operator walk-around covering fluid levels, lights, obvious damage, tyre visual, brake function check and bed condition before the shift. A monthly inspection is a two to four hour competent-person examination covering chassis weld walk, bed pivot pin play measurement, hub planetary checks, brake disc thickness measurement, retarder function testing under load, suspension cylinder seals, formal tyre and rim integrity checks to the AS 4457 series and a loaded bed lift function test. The pre-start catches daily symptoms, the monthly catches structural and mechanical drift before it fails under payload.

A dump truck monthly inspection must be completed by a competent person under the WHS Regulations 2011, which in practice means a qualified heavy-duty fitter, mechanical supervisor or plant mechanic with documented experience on rigid mining haul trucks and access to the OEM service literature. On NSW mines, MDG 15 (Mobile and transportable plant for use on mines and petroleum sites) is the Resources Regulator guideline for this plant, including wheels, rims and tyres, and where the mine needs a mechanical engineering control plan, that plan sets the competency required to work on plant. The operator may support the inspection but does not sign it off.

The primary standards are AS 20474.1:2025 and AS 20474.6:2025 (Earth-moving machinery - Safety - General requirements and dumpers), AS ISO 5006:2020 (Operator field of view), ISO 6165 (Earth-moving machinery basic types and terminology), the WHS Regulations 2011 (Part 5.1, including regulation 213 on maintenance and inspection of plant), and the Safe Work Australia Code of Practice for Managing Risks of Plant in the Workplace. AS 4457.1:2024 and AS 4457.2:2024 cover the maintenance and repair of off-the-road wheels, rims and tyres, and on NSW mines MDG 15 (Mobile and transportable plant for use on mines and petroleum sites) is the Resources Regulator guideline for this plant. OEM service literature from CAT, Komatsu and Liebherr supplies the technical reject criteria for brake disc thickness, suspension charge, and bed pivot wear.

Yes, the dump truck monthly inspection checklist is free to download as a PDF and use across any haul-truck fleet. If you want each monthly inspection scheduled per truck asset, completed on a mobile device with brake-disc and tyre measurements captured as data fields, photo evidence attached to every defect, and prioritised work orders raised automatically, MapTrack runs the full inspection programme alongside your OEM service intervals. Start a free trial at maptrack.com to load your haul fleet and schedule the first cycle.

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.

  • 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)

    Plant inspected, maintained and tested by a competent person following the manufacturer'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)

  • Earth-moving machinery - Off-the-road wheels, rims and tyres - Maintenance and repair, Part 1: Wheel assemblies and rim assemblies

    Edition: AS 4457.1:2024 (incl. Amd 1:2025)

    Maintenance and repair of off-the-road wheel and rim assemblies, the reference for the rim checks.

    Standards AustraliaSold by the publisher

  • Earth-moving machinery - Off-the-road wheels, rims and tyres - Maintenance and repair, Part 2: Tyres

    Edition: AS 4457.2:2024

    Maintenance and repair of off-the-road tyres.

    Standards AustraliaSold by the publisher

  • Work Health and Safety (Mines and Petroleum Sites) Regulation 2022 (NSW)

    Edition: Work Health and Safety (Mines and Petroleum Sites) Regulation 2022 (NSW), text as at 8 November 2025

    NSW mines: the mechanical engineering control plan covers plant inspection, testing and defect management.

    • Sch 2, s 2: Mechanical engineering control plan: controls for plant and structures over their life cycle, including inspection, testing and defect management.

    NSW Parliamentary Counsel's Office (NSW Legislation)

  • MDG 15: Mobile and transportable plant for use on mines and petroleum sites

    Edition: MDG 15, version 9 (April 2020)

    NSW Resources Regulator guideline for mobile plant on mines, version 9 (2020). Guidance, not law.

    NSW Resources Regulator

  • Earth-moving machinery - Safety, Part 6: Requirements for dumpers (ISO 20474-6:2017, MOD)

    Edition: AS 20474.6:2025

    AS 20474.6:2025: dumper design and construction safety requirements, not in-service inspection.

    Standards AustraliaSold 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 Monthly Inspection Checklist</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Chassis and front cross-member structural weld visual</li>
    <li style="margin:4px 0;">Rear axle housing weld and mounting integrity</li>
    <li style="margin:4px 0;">Dump-body (bed) pivot pin and bush play measurement</li>
    <li style="margin:4px 0;">Bed liner wear and structural cross-member condition</li>
    <li style="margin:4px 0;">Hoist cylinder rod, seal weep and mounting trunnion</li>
    <li style="margin:4px 0;">Hub planetary final drive oil level and leak check</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-monthly-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Dump Truck Monthly Inspection Checklist</a> by MapTrack</p>
</div>

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The MapTrack dump truck monthly inspection checklist contains 36 checks across 7 sections.

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MapTrack Dump Truck Monthly Inspection Checklist, https://www.maptrack.com/templates/dump-truck-monthly-inspection-checklist
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MapTrack. (2026). Dump Truck Monthly Inspection Checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/dump-truck-monthly-inspection-checklist

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