The Ultimate Truck Maintenance Checklist 2024

TLC Auto & Truck Repair Center
03/10/2024

Truck Maintenance Checklist

The sandwich that you just ate for lunch had most of its ingredients transported in a truck. The device that you’re reading this article was likely delivered on a truck. It wouldn’t be wrong to say that trucks make the world go round. After all, the trucking industry in the US is over $732 billion.

Trucks, like any other vehicle, require proper, timely maintenance. And when you have a fleet of dozens or hundreds of trucks, you need a more organized way to carry out maintenance. That’s where the truck maintenance checklist comes in handy! With a checklist, maintenance work can flow smoothly and keep the fleet running optimally.

In this post, you’ll find a truck maintenance checklist template for virtually every type of truck. So regardless of what your business niche is, keep reading to get your hands on comprehensive truck maintenance checklists.

Table of contents

What is a Truck Maintenance Checklist?

A truck maintenance checklist lists down the maintenance tasks to ensure that all the parts and functionalities of a truck are running properly. Through these checklists, truck mechanics can check if there are any faults in need of repair or any parts in need of replacement.

Most commonly, truckers and mechanics use the truck preventive maintenance checklist that ensures there are no unexpected problems while the truck is on the road. However, there are also other types of truck maintenance, such as demand maintenance and crisis maintenance.

These checklists may be further divided into different categories, like the hood, cab, chassis, etc. Normally, the tasks on the list are either grouped by the area/part of the truck. Some checklists follow a priority-based order.

What are the Benefits of a Truck Maintenance Checklist?

Whether you have one truck or a fleet of them, having a checklist for maintenance can streamline the maintenance process. With a checklist in hand, mechanics can check all the parts without missing out on anything, which may later become a problem.

Checklists also provide the right order of maintenance activities that ultimately save time. As a result, the overall efficiency of the process increases. Of course, the last thing any business relying on trucks wants is for their trucks to be sitting idle in the garage for the sake of maintenance.

Most importantly, a truck maintenance checklist and maintenance, in general, can save your business repair costs. By detecting problems early on, businesses can prevent serious damage to the truck and avoid expensive repairs as well as downtime.

Furthermore, it can help prevent accidents and ensure compliance with road safety standards. In the trucking industry, federal and state regulations may mandate certain maintenance checks. For instance, the Environmental Protection Agency (EPA) requires vehicle inspection and maintenance (I/M) regarding emissions.

Finally, having a well-maintained fleet can lead to business growth and client satisfaction. That’s because a well-maintained fleet translates into timely deliveries, fewer problems on the road, and better driver safety.

Truck Maintenance Checklists

Checklists vary depending on the type of truck you are using. While some maintenance items are universal, others are more specific to the truck type, design, or use.

Here we have complied maintenance checklists for different commercial trucks. We’ve created a free Truck Maintenance Checklist excel file here.

Alternatively, download our Truck Maintenance Checklist PDF here: Truck Maintenance Checklist PDF

Heavy-duty truck maintenance is much more comprehensive than your average transport truck. So, here’s a complete list of heavy-duty truck preventive maintenance checklists:

Identification

Registration number
Vehicle identification number (VIN) or Chassis number
Engine number
Make and model year
Body type
Cylinder
Mileage (odometer reading)

Engine and Exhaust

Brakes

Tires and Wheels

Body

Panels and fittings
Cabin condition
Number plates
Mudguards
Mudflaps
Rear marking plates
Front underrun protection
Horn
Chassis

Seating Safety

Couplings

Fifth Wheel/Ballrace
Pin Couplings/Pintle Hooks
Towbar
Safety Chains/Cable Attachments
Steering and Suspension
Steering Box/Pump
Steering Wheel
Free Play
Arms/Linkages/Components
Shock Absorbers
Towing Attachments

Lights, Cameras, Reflectors, and Mirrors

Headlights (both low and high beam)
Fog lights
Brake lights
Reverse lights
Blinkers/hazards (right/left, front and rear)
Front position light
Daytime running light
Clearance lights (front and rear)
Number plate lights
Taillights
Side marker lights
Camera (front and/or rear)
Dashcam
Reflectors (all sides)
Rearview mirrors
Windscreen
Windows and window controls
Glazing
Wipers, demisters, and washers

Engine oil level and state
Engine oil filter
Air filter
Transmission fluid
Brake fluid
Driveshafts or CV joints
Drive belt
Serpentine belt
Suspension
Steering
Fuel system
Coolant/Cooling system
Transmission and engine mounts
Tires
Wheels/rims
Exhaust system
Electrical systems
Braking system
Undercarriage and frame
Seats and seatbelts
Windshield, wipers, and wiper fluid
Horn
Headlights, tail lights
Brake lights, blinkers, and reverse lights
Auxiliary systems

Diesel trucks are highly versatile trucks with both personal and commercial models available in the market. However, when it comes to maintenance, there’s not much difference between diesel trucks and gasoline cars. That said, some components are unique to a diesel vehicle, for example, diesel exhaust fluid (DEF).

Here’s a simple checklist for diesel trucks:

Engine oil
Engine oil filter
Air filter
Fuel filter
Diesel exhaust fluid
Coolant
Engine cleaning and tune-up

Here are some tips regarding diesel truck maintenance:

Diesel engines typically need an oil change every 5000 to 6000 miles, varying by model. However, you may need to replace it sooner if you use the truck frequently and that too for heavy-duty tasks.
Air filters can easily be cleaned if they are dirty, but after a while, they may need replacement. If it’s too clogged and dirty, buy a replacement filter and replace it.
Fuel filters need replacement every 10,000 to 15,000 miles. There are two fuel filters in diesel engines.
Check the level of coolant from time to time and top it up if it’s low, as it will keep the diesel engine from overheating. Also, make sure to use the right coolant and dilute it if it’s not diluted already.
Diesel trucks, especially those that do a lot of hauling or towing (for example, camper or boat), need engine cleaning and tuneup more frequently. Prolonged accumulation of dirt and grime can take a toll on engine performance and fuel economy.

Bucket trucks serve a variety of purposes, fixed with a hydraulic boom and bucket to carry workers up. From electric companies to utility crews, bucket trucks are used in every town and city. Of course, these also require maintenance, not just for the engine and other parts of the truck but also the boom and bucket.

Visual Check

Boom condition – welds, rust, damage
Boom rest/cradle; pins, rings, bolts
Bucket – mounting, door latch, safety
Cylinders & hoses
Hydraulic leaks – under truck & boom
Loose/missing bolts, nuts, snap rings, cotter pins
Outriggers
Pedestal mounting bolts
Safety decals
Snow or ice buildup
Tire condition & inflation
Turntable – bucket van Lights:
Welds; look under the vehicle

Body Integrity

Pedestal Mounting Bolts

Four mounting bolts connect the pedestal to the bed/frame
Equipment Colored dye/paint mark on bolt and lock nut
¾" grade 8 bolts
Torque to 160#
Cargo Area Access
Pedestal Collapse – Loose & Missing Bolts

Fluids

Operation Controls

Lower & upper controls Boom
Test hydraulic and 12 volts electrical
"Safe operating condition"
Test all switches/controls
Emergency stop button works
Defroster
Wipers
Horn
Emergency Brakes
Service Brakes
Seatbelts

Lights

Safety & Emergency

Wheel chocks – minimum of 2
Outrigger pads/mats
Portable fire extinguisher – DOT 5 B:C
Reflective triangles
Petroleum spill kit
Traffic cones
Fall Protection
Electrical PPE
Spare fuses – 1 for each amp circuit
Warning signs

Food trucks are essentially like any other truck, except these are equipped with food appliances as well. Therefore, the maintenance checklist is a little different. Aside from the regular checks for the truck itself, you should also check the equipment on the truck for safety reasons.

Visual Inspection

Emergency Equipment Check

Tire jack/pump
Jumpstart cables
Ice scraper and road salt (for winters)
Flashlight
Emergency tool kit
First aid kit
Portable fire extinguisher
Spare tire (air pressure in it)

Fluids

Other Periodic Checks

Engine cleaning
Cabin cleaning
Seats and seatbelts
Dashboard warning lights
Interior lights
Headlights, taillights, flashers, blinkers, backup lights, parking lights
Cameras (both vehicle and security)
Braking system (parking brake, braking pads, ABS)
Horn
Tow bar
Battery

Daily Safety Checks

While fire trucks may not be utilized every day, they serve a very important purpose. So they have to be in good condition at all times. This requires proper, timely maintenance of the vehicle as well as its fire extinguishing equipment.

Engine oil/filter
Fuel leaks
Fluid leaks
Braking system
Tires air pressure
Power steering fluid
Coolant level
Hoses
Windshield washer fluid level
Seat belt buckles
Engine sound
Suspension
Battery fluid and terminals
Gauges (check for normal ranges)
Control system (intercom)
Signal lights
Audio devices
Headlights, taillights
Brake lights, reverse lights, parking lights
Signal lights
Emergency lights (strobe, flashing)
Siren

Forklifts or forklift trucks are used in warehouses, manufacturing plants, and factories. While these are essentially heavy machinery, these do require regular maintenance like that by any other type of truck.

Minor Maintenance (250 hours of use)

Remove filler caps to release any additional pressure
Replace engine oil and oil filter (see user manual)
Top up your coolant and use antifreeze for winters
Clean the engine cooling system
Vacuum or replace the air filter
Inspect the drive or fan belt for damage and tension
Check the hoses for any leaks
Refuel gas and check for leaks
Check the fuses in the fuse box
Add AdBlue
Bleed the fuel system
Refuel LPG and check for leaks
Tighten the cylinder head bolts
Adjust engine idle speed and ignition timing
Check the meters and warning lights
Listen to the engine for erratic sounds
Check the color of the exhaust gases

Major Maintenance (500 hours of use)

Change the fuel filter/clean the LPG filter
Check and adjust valve clearance if needed
Replace the spark plugs for gas-run forklifts
Drain the water separator
Clean the radiator
Clean the radiator exterior
Replace the fuel filter
Replace the points, the condenser, and the set timing

Major maintenance (2,000 hours of use)

Replace the coolant
Check and replace fuel filter, fuel strainer element, and water separator
Replace the distribution belt and other seals such as the gasket seal
Clean or replace the interior ventilation filter
Torque the engine head bolts and manifold nuts

Fork Maintenance (250 hours of use)

Tighten loose nuts and bolts
Clean the mast and lubricate it if needed
Lubricate all lubrication points of the frame
Visually check the mast and load protector for deformation
Check the operation of the mast by using the lifting and tilting levers
Check the shock absorber
Lubricate the chain

Garbage trucks should have a daily visual inspection, as well as periodic (weekly, monthly, and annual) maintenance checks for the health and condition of the truck. Garbage trucks also need frequent cleaning and subsequent checks.

Daily Inspection

Body condition
Back up alarm
Tire inflation
Check all gauges, including oil and temperature
Visually check rims, wheel lug nuts
Windshield washer operation
Steps and grab handles
Brakes
Look for indications of oil leaks
Horn
Mirrors and glass
Back up camera (if applicable)
Hydraulic tank and gauge
Heater, window defroster (for winters)
Front, rear, and marker lights
Mirror alignment
Fuel tank
Hydraulics operation
Hydraulic leaks
Work spotlights
Fire extinguisher

Periodic Maintenance

Engine oil
Engine oil filter
Air filter
Transmission fluid
Brake fluid
Hydraulic lines
Coupling devices
Driveline
Exhaust system

Summary

A truck maintenance checklist can be a lifesaver not just metaphorically but literally. Doing proper maintenance on trucks like bucket trucks and fire trucks can ensure these vehicles don’t fail in times of need.

Similarly, for other trucks, be it a personal diesel truck or a fleet of heavy-duty trucks hauling containers, maintenance is the key to ensuring great productivity and reliable safety.

A standardized maintenance checklist is hard to find. But you can use the checklists above and make your own to use periodically. Some maintenance may not be needed for months, while some items should be checked daily, so create lists accordingly.

In addition to checking and maintaining truck parts, it’s equally important to ensure safety features are in working conditions. Checking warning lights, brakes, reflectors, and fire extinguishers regularly can reduce the chances of accidents.

Regardless of the type of truck you have for personal or business use, maintain a maintenance history digitally or in a physical format. This will come in handy for subsequent maintenance checks. This will help replace parts timely, such as engine oil, filters, coolant or antifreeze, windshield cleaner, and other fluids.