Detailed Maintenance Procedures
Follow these structured procedures for each major truck component to ensure thorough inspection and maintenance. Regular servicing according to these steps extends vehicle lifespan, improves safety, and ensures DOT compliance.
- Drain engine oil when warm for complete removal
- Replace oil filter and verify gasket is not stuck
- Inspect air filter and replace if restriction indicator shows
- Service fuel filter system according to manufacturer specs
- Check all belts for proper tension using gauge tool
- Inspect entire cooling system for leaks under pressure
- Verify transmission fluid level with engine at operating temperature
- Check differential oil level through fill plug
- Inspect engine mounts for cracks or deterioration
- Check turbocharger for excessive shaft play and oil leaks
- Perform measured brake stroke test on all chambers
- Remove dust covers and measure brake lining thickness
- Inspect drums/rotors for cracks, heat checking, and grooves
- Test air system for pressure drop (max 3 psi per minute)
- Verify low air warning activates at 60-70 psi
- Check that spring brakes apply automatically at 20-40 psi
- Drain air tanks and check for excessive moisture
- Test antilock brake system indicator light cycle
- Inspect all brake hoses for chafing, cracks, or leaks
- Verify trailer brake application and release timing
- Measure tire tread depth at three points across each tire
- Check tire pressure when cold with calibrated gauge
- Inspect sidewalls for cuts, bulges, and penetrations
- Remove debris from between dual tires
- Examine wheel rims for cracks, dents, and bent flanges
- Verify all lug nuts are present and tightened to spec
- Check valve stems for damage and ensure caps are present
- Inspect hub oil level through sight glass or fill port
- Test wheel bearing play with dial indicator when possible
- Correct tire inflation to match load and application
- Measure battery voltage under load and at rest
- Clean battery terminals with wire brush and solution
- Check alternator output voltage at idle and high rpm
- Verify starter motor amperage draw during cranking
- Test all exterior lights, signals, and reflectors
- Inspect wiring harness for rubbing, damage, or exposure
- Verify dash warning lights illuminate during key cycle
- Test horn operation and brightness control
- Operate wipers at all speeds and test washer function
- Apply dielectric grease to all exposed connections
- Inspect all steering linkage with wheels turned
- Check power steering fluid level and condition
- Measure kingpin play with proper dial indicator
- Inspect all leaf springs for cracks and shifted leaves
- Test air suspension height control valves
- Verify air bags inflate evenly without leaks
- Check shock absorbers for signs of leakage or damage
- Inspect all suspension U-bolts for proper torque
- Check frame rails and crossmembers for cracks
- Grease all steering and suspension fittings
- Clean old grease from fifth wheel plate surface
- Inspect mounting brackets for cracks or looseness
- Check all mounting bolts for proper torque
- Test locking mechanism operation and security
- Verify release handle operates freely
- Inspect kingpin locking jaws for excessive wear
- Check plate surface for gouges or uneven wear
- Test for excessive up/down movement when coupled
- Apply fresh lubricant to plate surface and pivot points
- Verify safety chain attachments are secure
- Pressure test cooling system when cold
- Test coolant strength with refractometer
- Check coolant pH level with test strips
- Inspect radiator for external damage and blocked fins
- Check all hoses for softness, cracks, or bulges
- Verify radiator cap holds proper pressure
- Test thermostat operation during warm-up
- Check water pump for signs of seal leakage
- Inspect fan clutch for proper engagement
- Verify coolant level sensor operates correctly
- Inspect cab mounts and pivot points for wear
- Check door operation, locks, and weatherstripping
- Adjust mirrors for proper visibility
- Inspect windshield for cracks and wiper damage
- Test all seat adjustments and mounting security
- Verify seat belt operation and attachment points
- Test HVAC system in all operating modes
- Check all gauges for proper operation
- Verify emergency equipment is present and serviceable
- Test all interior lights and controls
Truck Maintenance Pro Tips
- Document Everything: Maintain detailed service records for each vehicle including dates, mileage, parts replaced, and technician notes. This documentation is essential for warranty claims, DOT compliance, and establishing resale value.
- Preventive Maintenance Scheduling: Create tiered PM schedules (A, B, C inspections) based on mileage or time intervals that follow manufacturer recommendations. Digital scheduling through fleet management software ensures no service is missed.
- Driver Inspection Training: Develop a comprehensive driver daily inspection program. Professional drivers can identify many problems early if properly trained on what to look and listen for during pre-trip and post-trip inspections.
- Part Quality Matters: Always use OEM or high-quality aftermarket parts for critical systems like brakes, steering, and emissions components. The small premium in cost is offset by longer service life and reduced downtime.
Streamline Fleet Maintenance with HVI
Implementing this comprehensive Truck Maintenance Procedure is essential for ensuring fleet reliability, regulatory compliance, and optimal vehicle performance. Thorough maintenance extends equipment life, improves safety records, and significantly reduces costly roadside breakdowns and downtime.
The HVI APP (Heavy Vehicle Inspection and Maintenance software) offers a powerful solution for tracking and managing your fleet maintenance procedures. HVI's platform has been specifically designed for commercial vehicle maintenance tracking, providing digital documentation, real-time alerts, automated scheduling, and comprehensive historical records for each vehicle in your fleet.
With the Heavy Vehicle Inspection and Maintenance software, fleet managers can easily document inspections, schedule maintenance tasks, and generate detailed reports for DOT compliance and warranty claims. Experience the benefits of streamlined fleet maintenance management with HVI today.