Complete Truck Maintenance Checklist That Every Perth Fleet Needs

Your truck breaks down in the middle of a mine site with no workshop nearby. Labour stops, deadlines slip and costs climb. Sound familiar? For fleet managers and drivers in WA, a single preventable failure can mean thousands in lost revenue. That’s why truck maintenance shouldn’t be left to chance.

This post gives you the complete truck maintenance checklist every Perth fleet needs. You’ll find clear daily pre-start checks, practical weekly, monthly, and annual inspection routines, plus a printable checklist for on-site use. It’s designed for busy operators who want fewer breakdowns, lower repair bills, and smoother compliance.

Follow this truck inspection guide and turn costly surprises into planned maintenance wins.

What is a Truck Maintenance Checklist? Why It Matters?

A preventative truck maintenance checklist is a simple but powerful management tool that organises and tracks routine inspections and repairs for every vehicle in your fleet. It lists clear, repeatable tasks, from engine and brakes to tyres, fluids and lights, so drivers and technicians know exactly what to check and when.

Used consistently, a preventive checklist turns guesswork into a predictable truck repair and maintenance routine that keeps vehicles safe and roadworthy.

Key benefits of a truck preventive maintenance checklist

• Reduces repair costs by catching minor issues before they become expensive problems.
• Prevents downtime with planned, proactive maintenance.
• Ensures inspections are consistent, so nothing is missed.
• Simplifies tracking with a clear service history for every truck.
• Speeds up fault diagnosis and resolves recurring issues faster.
• Supports compliance and audits with documented inspections and repairs.
• Extends vehicle lifespan by reducing wear and maximising performance.

Now, let’s walk you through the practical checklists every fleet manager should use.

The Ultimate Truck Maintenance Checklist (Daily, Weekly, Monthly & Annual Checks)

A well-planned heavy vehicle maintenance checklist is essential for keeping trucks safe, reliable, compliant, and productive, especially in Perth’s demanding construction zones and mining sites. Find below a comprehensive truck inspection checklist covering daily pre-start inspections, weekly and monthly servicing, and seasonal or annual maintenance tasks.

Daily Truck Maintenance Checklist (Pre-Start & Pre-Trip)

Daily inspections are critical for identifying safety risks and preventing unexpected breakdowns. These checks should be completed before every shift or trip.

Must-Do Daily/Pre-Trip Truck Inspection Checks

These are the top priority checks every driver must complete before hitting the road:

• Tyres – Check pressure, tread, and damage (cuts, bulges, debris)
• Fluids – Engine oil, coolant, brake fluid, power steering, fuel, DEF
• Brakes – Confirm air/brake pedal response, brake lights, ABS warning lights
• Lights & Indicators – Headlights, tail lights, brake lights, hazard lights, turn signals
• Mirrors & Windscreen – Clean, properly adjusted, no cracks or chips
• Visible Leaks & Damage – Check under truck and engine bay for oil, coolant, fuel, hydraulic leaks; inspect chassis and panels

These priority checks cover the essentials, but a thorough daily inspection goes a bit further. Below, we break down detailed daily/pre-trip tasks to keep your truck fully road-ready.

Tyre Care

• Check tyre pressure: Ensure all tyres are inflated to the manufacturer’s recommended PSI for the load and operating conditions.
• Under-inflated tyres increase heat build-up and blowout risk
• Over-inflated tyres reduce traction and braking performance
• Inspect tyres for damage:
• Cuts, punctures, cracks, bulges
• Uneven or excessive tread wear
• Embedded stones or debris

Early tyre checks help prevent roadside failures and reduce reliance on emergency mobile truck tyre repairs.

Engine & Fluid Checks

• Engine oil level: Check using the dipstick and top up if required
• Coolant level: Ensure coolant is within the recommended range
• Brake fluid level: Low levels may indicate leaks or worn brake components
• Power steering fluid: Check for safe steering response
• Fuel and DEF levels (where applicable)
• Check for leaks: Inspect under the truck and engine bay for oil, fuel, coolant, or hydraulic leaks

Cooling System – Daily Visual Checks

• Coolant level and concentration
• Radiator condition and cleanliness
• Coolant hoses (no cracks, swelling, or leaks)
• Radiator cap condition and pressure seal
• Water pump operation (no leaks or unusual noise)
• Fan clutch engagement
• Thermostat operation
• DEF fluid quality and contamination

Exterior Inspection

• Lights and indicators:
  • Headlights, tail lights, brake lights
  • Indicators, clearance lights, hazard lights
• Windshield and mirrors:
  • Clean, properly adjusted, no cracks or chips
• Reflectors and number plates: Visible and secure

Daily Pre-Trip Inspection Checklist

This walk-around inspection ensures the truck is road-ready before departure.

Exterior Walk-Around

• Inspect tyres for correct inflation, tread depth, cuts, or bulges
• Confirm all lights are working correctly
• Ensure mirrors are clean, secure, and properly adjusted
• Inspect windscreen for cracks, chips, or dirt that may obstruct vision

Fluid Levels

• Engine oil within safe operating range
• Coolant topped up if required
• Brake fluid and power steering fluid at correct levels
• Look for signs of leaks around hoses and reservoirs

Brake System Checks

• Confirm air pressure builds to safe operating range
• Press brake pedal to check for firmness (no sponginess)
• Ensure brake lights illuminate when pedal is pressed

Brake inspection items:

• Brake pad or shoe thickness
• Brake drum or rotor condition
• Air brake system leakage test
• Brake chamber and pushrod stroke measurement
• Air dryer operation and purge function
• Air governor cut-in and cut-out pressure
• Brake hoses and air lines condition
• ABS system warning lights and operation
• Parking brake holding ability

Leaks & Visible Damage

• Check for fuel, oil, coolant, or hydraulic leaks
• Inspect chassis, bumpers, guards, and panels
• Look for loose, missing, or damaged components that may pose safety risks

Weekly Truck Maintenance Checklist

Weekly checks allow for deeper inspection and early detection of wear-related issues.

Brake System

• Inspect brake pads, shoes, discs, and drums for wear or damage
• Check brake fluid condition and level
• Inspect air lines, chambers, and fittings

Tyre Maintenance

• Rotate tyres where applicable to ensure even wear
• Measure tread depth and confirm legal compliance
• Inspect tyres for uneven wear patterns

Wheel and tyre checks:

• Tyre pressure check and adjustment
• Tread depth measurement (all positions)
• Tyre condition (cuts, bulges, irregular wear)
• Wheel rim condition (cracks or dents)
• Wheel lug nuts condition and torque
• Valve stems and caps present
• Hub oil level and condition
• Wheel bearing condition and adjustment

Exterior & Interior Care

• High-pressure truck wash to remove dirt, salt, and grime
• Clean cabin interior to improve driver comfort and visibility
• Inspect steps, handrails, and access points for safety

Battery & Electrical Checks

• Inspect battery terminals for corrosion
• Ensure cables are tight and undamaged
• Confirm battery is securely mounted
• Test alternator output and belt condition
• Check starter motor operation

Electrical systems to verify:

• Headlights, tail lights, indicators
• Clearance lights and reflectors
• Brake and hazard lights
• Horn operation
• Wipers and washer system
• Dashboard warning lights and gauges

Load Security & Trailer Connections

• Inspect straps, chains, and locking mechanisms
• Confirm load is evenly distributed and secure
• Check trailer coupling, safety chains, and electrical plugs
• Verify trailer brake and lighting operation

Monthly Truck Maintenance Checklist

Monthly servicing helps identify developing issues before they cause downtime.

Fluids & Replacements

• Transmission fluid level and condition
• Power steering fluid level
• Differential oil level and condition
• Replace contaminated or burnt-smelling fluids immediately

Engine Oil & Filters (As Per Manufacturer)

• Engine oil level and condition
• Oil filter replacement verification
• Air filter condition and restriction indicator
• Fuel filter condition and replacement
• Serpentine belt condition and tension

Engine & Driveline Inspection

• Engine mounts condition
• Turbocharger inspection (leaks, shaft play)
• Exhaust system mounting and integrity

Battery & Charging System

• Inspect battery for corrosion
• Test charge level and load capacity
• Secure battery mounting

Belts, Hoses & Wiring

• Inspect drive belts for cracking or fraying
• Check hoses for bulges, leaks, or soft spots
• Inspect wiring for corrosion, wear, or loose connections

Suspension & Steering

• Steering linkage and components
• Power steering fluid condition
• Kingpins and wheel bearing play
• Leaf springs, hangers, and bushes
• Air suspension components and ride height
• Shock absorbers (no leaks)
• U-bolts and torque rods
• Wheel alignment verification

Exhaust System

• Inspect exhaust pipes, clamps, and muffler
• Check for leaks, cracks, corrosion, or loose fittings
• Repair exhaust issues promptly to avoid emissions and performance problems

Seasonal / Annual Truck Maintenance Checklist

Annual inspections are critical for long-term reliability and compliance.

Complete Truck Inspection & Detailing

• Full vehicle detailing to expose rust or structural damage
• Inspect chassis, frame, mounts, and underbody
• Review corrosion-prone areas (especially mine or coastal environments)

Major Service Items (As Per Manufacturer)

• Engine oil and filter change
• Full fluid replacements where required
• Comprehensive driveline and engine inspection
• Cooling system flush if recommended

Suspension, Steering & Exhaust

• Full suspension and steering assessment
• Steering alignment check
• Exhaust system inspection and mounting review

Emergency & Roadside Preparedness Review

• Review roadside truck tyre assistance plans
• Update emergency contact lists
• Confirm availability of 24/7 mobile truck services
• Check emergency kits and safety equipment

Emergency Preparedness Checklist (Roadside Readiness)

Even with a complete truck maintenance checklist, breakdowns can still occur — especially on long-haul routes, remote areas, or mine sites. A well-prepared truck reduces downtime, improves driver safety, and speeds up roadside recovery.

Every truck should carry the following emergency essentials:

• Spare tyre and fitting tools: A roadworthy spare tyre and correct tools allow temporary repairs and reduce reliance on emergency callouts.
• Emergency contact details: Keep up-to-date contact numbers for emergency truck tyre replacement, mobile truck tyre service near you, and fleet or depot supervisors. Store them digitally and in hard copy.
• First aid kit: A compliant first aid kit is essential for handling minor injuries until professional help arrives.
• Basic safety equipment: High-visibility vest, warning triangles or cones, torch, and fire extinguisher for roadside safety.

Strong emergency preparation supports reliable truck repair and maintenance practices and keeps drivers ready for unexpected situations.

Record-Keeping & Compliance (Legal & Operational Requirement)

Accurate maintenance records are essential for compliance and fleet accountability. Transport authorities often require documented proof of inspections, truck servicing and repairs, and defect rectifications to ensure vehicles meet road safety standards.

Truck maintenance records should clearly include:

• Date of inspection or service
• Work performed or issues identified
• Parts repaired or replaced
• Odometer or engine hours
• Name of the driver or technician responsible

Proper documentation helps:

• Pass roadside inspections and audits
• Avoid fines, penalties, and compliance breaches
• Support warranty and insurance claims
• Track recurring faults and reduce repair costs
• Improve resale value with a verified service history

Using a structured complete truck servicing checklist alongside organised records ensures consistency and legal protection.

Common Truck Maintenance Mistakes to Avoid

Avoiding common mistakes can significantly avoid breakdowns and unplanned repairs:

❌ Skipping checks due to time pressure: Missing daily or pre-trip inspections often leads to preventable safety failures and roadside breakdowns.

❌ Ignoring early warning signs: Small leaks, unusual noises, vibrations, or dashboard warnings are early indicators of serious mechanical issues.

❌ Using poor-quality or non-genuine parts: Substandard components may cost less initially but wear faster and compromise safety, especially in brakes, suspension, and steering systems.

Consistent inspections and professional truck repair and maintenance services help avoid these costly errors.

Signs Your Truck Needs Immediate Inspection

Even with regular servicing, some warning signs require urgent action:

➣ Warning lights or alerts: Dashboard warnings should never be ignored, as they often indicate critical system failures.

➣ Unusual noises: Grinding, knocking, or squealing may indicate brake wear, drivetrain issues, or air leaks.

➣ Excessive vibrations: Vibrations during braking or steering can signal suspension, wheel, or brake faults.

➣ Fluid leaks: Oil, coolant, or brake fluid puddles under the truck can indicate serious leaks that need immediate attention.

➣ Smoke or unusual smells: Exhaust smoke, burning smells, or unusual odors may point to engine, electrical, or brake problems.

Addressing these signs early prevents breakdowns, protects drivers, and keeps repairable trucks safely operational.

Tired of losing hours — or thousands of dollars — every time a truck breaks down on a remote site?

Get 24/7 Mobile Truck Maintenance, Repairs & Services at West Fleet Care

West Fleet Care keeps Perth fleets moving. Our 24/7 mobile truck services provide fast, on-site repairs; tyre replacements, brake and suspension fixes, emergency diagnostics and roadside support, so you don’t wait for a workshop.

Book a maintenance audit and we’ll review your truck maintenance checklist, identify urgent issues, and recommend a tailored service plan that reduces downtime and repair costs.

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FAQs

• How often should I inspect my truck?

Perform a daily pre-start check every shift. Add weekly visual inspections and monthly system checks. Follow manufacturer service intervals (5k/10k km or hours) for full servicing.

• What is the most important part of truck maintenance?

All systems matter, but the brake system is the single most critical safety component — ensure brake inspections and fluid checks are done and recorded.

• What should be included in every daily (pre-start) truck maintenance checklist?

Tyre pressure and damage, engine oil level, coolant and brake fluid, lights and indicators, mirrors and windscreen, basic brake test, and a look for visible leaks or damage.

• What monthly checks should fleet managers schedule?

Monthly checks should include transmission and power steering fluids, filters (air/fuel/oil), battery and charging system tests, belts and hoses inspection, suspension and wheel bearing checks, and exhaust integrity.

• What should be checked during a truck’s pre-trip inspection?

Brakes, tyres, lights, steering, mirrors, windshield wipers, horn, fluid levels, and a quick visual under the chassis for leaks or loose parts.

• How often should truck tyres be checked?

Check tyre inflation and visible damage daily; measure tread depth and inspect for uneven wear weekly or per route intensity. Rotate tyres according to manufacturer or fleet policy to ensure even wear.

• How often should engine oil be checked?

Check engine oil weekly or before long trips; change oil as per manufacturer recommendations based on km or operating hours and duty cycle.

• What should be included in your emergency preparedness kit?

A spare tyre with fitting tools, first aid kit, reflective triangles or cones, high-visibility vest, torch, basic tool kit, fire extinguisher, and printed + digital emergency contact numbers (including 24/7 mobile truck services).