Maintenance Inspection Schedule

Pretrip 2,000 Hours Annual/ 3,000 Hours Inspect/Service These Items Completed
Microprocessor
•     Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).  
Engine
•     Check fuel supply.  
• •   Check engine oil level.  
• •   Check condition and tension of belts every 2,000 hrs or 6 months (whichever occurs first). Replace if excessive wear found.  
  •   Check air cleaner hose for damage.  
  •   Inspect and clean electric fuel pump filter.  
  •   Check engine coolant level every 1,000 hours or 6 months (whichever occurs first).  
  •   Check that engine coolant antifreeze protection is at –40 F (–40 C) every 1,000 hours or 6 months year (whichever occurs first).  
  •   Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year (whichever occurs first)  
  •   Change EMI 2000 (black) fuel filter.  
  •   Change engine oil and oil filters (hot). Requires oil with API Classification CJ-4 or CK-4 (ACEA Rating E6 for Europe) and EMI 2000 bypass oil filter.

Note See Service Bulletin SB803 - T-90 Series Oil Bypass Filter Update. Units built September 30, 2020 and after do not have an oil bypass filter.

  
  •   Check restraining mount (snubber) pre-load adjustment.  
    • Drain water from fuel tank and check vent.  
    • Check and adjust engine speeds (high and low speed).  
    • Check condition of engine mounts.  
    • Test fuel injection nozzles at least every 3,000 hours. Based on EPA 40 CFR Part 89.  
    — Adjust engine valve clearance every 1,000 hours.  
    — Replace fuel return lines between fuel injection nozzles every 10,000 hours or sooner, as required.  
    — Change ELC (red) engine coolant every 8 years or 15,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank.  
Electrical
•     Check controller for alarms.  
•     Run pretrip test.  
•     Check battery voltage.  
  •   Inspect battery terminals and electrolyte level.  
  •   Tighten all electrical connections (where applicable) and inspect all harnesses, wires and terminals for damage or corrosion. If corrosion is present, clean terminals with electrical contact cleaner.  
    • Inspect alternator bearings and brushes.*  
    • Inspect electric motor bearings (Model 50).*  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Refrigeration
• •   Check refrigerant level.  
  •   Check compressor oil level.  
    • Check discharge and suction pressures.  
    • Check compressor efficiency.  
    — Replace dehydrator and compressor oil filter only when the refrigeration system is opened for repair.  
Structural
• •   Visually inspect unit for fluid leaks.  
• •   Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).  
  • • Inspect clutch for shoe and anchor bushing wear with a mirror. Check bearings.*  
    • Inspect idlers, fanshafts, and jackshaft (if so equipped) for leakage and bearing wear.*  
    • Clean entire unit including condenser coils, evaporator coils, and defrost drains.  
  • • Check all unit, fuel tank, engine, and electric motor mounting bolts, brackets, lines, hoses, etc.  
  •   Inspect drive belt condition and tension  
  •   Inspect evaporator and condenser fan hardware  
    • Inspect fanshaft oil level  
    — Replace drive belts every 4,000 hrs.  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Pretrip 1,200 Hours 2,000 Hours Annual/ 3,000 Hours Inspect/Service These Items Completed
Microprocessor
•       Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).  
        Engine  
•       Check fuel supply.  
• •     Check engine oil level.  
• •     Check condition and tension (1,200 hrs) of belts.  
• •     Check engine oil pressure hot, on high speed.  
• • • • Listen for unusual noises, vibrations, etc.  
  •     Check air cleaner hose for damage.  
  •     Inspect and clean electric fuel pump filter.  
  •     Check engine coolant level every 1,000 hours or 6 months (whichever occurs first).  
  •     Check that engine coolant antifreeze protection is at –30 F (–34 C) every 1,000 hours or 6 months year (whichever occurs first).  
    •   Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year (whichever occurs first)  
    •   Change EMI 2000 (black) fuel filter.  
    •   Change engine oil and oil filters (hot). Requires oil with API Classification CJ-4 or CK-4 (ACEA Rating E6 for Europe) and EMI 2000 bypass oil filter.  
    •   Check restraining mount (snubber) pre-load adjustment.  
      • Drain water from fuel tank and check vent.  
      • Check and adjust engine speeds (high and low speed).  
      • Check condition of engine mounts.  
      • Test fuel injection nozzles at least every 3,000 hours. Based on EPA 40 CFR Part 89.  
      — Adjust engine valve clearance every 1,000 hours.  
      — Replace fuel return lines between fuel injection nozzles every 10,000 hours or sooner, as required.  
      — Change ELC (red) engine coolant every 5 years or 12,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank.  
Electrical
•       Check controller for alarms.  
•       Run pretrip test.  
•       Check battery voltage.  
  •     Inspect battery terminals and electrolyte level.  
  •     Inspect wire harness for corrosion, damaged wires or connections.  
      • Inspect alternator bearings and brushes.*  
      • Inspect electric motor bearings (Model 50).*  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Refrigeration
• •     Check refrigerant level.  
  •     Check compressor oil level.  
      • Check discharge and suction pressures.  
      • Check compressor efficiency.  
      — Replace dehydrator and compressor oil filter every two (2) years.  
Structural
• •     Visually inspect unit for fluid leaks.  
• •     Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).  
  •   • Inspect clutch for shoe and anchor bushing wear with a mirror. Check bearings.*  
      • Inspect idlers, fanshafts, and jackshaft (if so equipped) for leakage and bearing wear.*  
      • Clean entire unit including condenser coils, evaporator coils, and defrost drains.  
  • • • Check all unit, fuel tank, engine, and electric motor mounting bolts, brackets, lines, hoses, etc.  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Pretrip 750
Hours		 Annual/ 2,000 Hours Inspect/Service These Items Completed
Microprocessor
•     Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).  
Engine
•     Check fuel supply.  
•     Check engine oil level.  
• • • Check engine coolant level.
    Caution
  • Hazardous Pressures
  • Do not remove expansion tank cap while coolant is hot.
  
• • • Inspect belts for condition and proper tension.  
• • • Check engine oil pressure hot, on high speed.  
• • • Listen for unusual noises, vibrations, etc.  
    • Change engine oil (hot). (2000 hrs with bypass filter or synthetic oil).  
  • • Change oil filters.  
  • • Clean and service crankcase breather.  
  • • Drain water from fuel tank and check vent.  
  • • Replace fuel filter  
  • • Replace dry type air cleaner element.  
  • • Inspect/clean electric fuel pump filter.  
  • • Check air cleaner hose for damage.  
    — Check that engine coolant antifreeze protection is at –30 F (–34 C) every 1,000 hours or 6 months year (whichever occurs first).  
    — Adjust engine valve clearance every 1,000 hours.  
    • Check and adjust engine speeds.  
    • Check condition of engine mounts.  
    • Check restraining mount (snubber) pre-load adjustment.  
    — Clean and test fuel injection nozzles every 3,000 hours.  
    — Replace fuel return lines between fuel injection nozzles every 10,000 hours or sooner, as required.  
    — Change ELC (red) engine coolant every 5 years or 12,000 hours.  
Refrigeration
• • • Check refrigerant level and compressor oil condition.  
• • • Check for proper suction pressure.  
    • Check throttling valve regulating pressure on defrost.  
    • Check compressor oil level.  
    • Check compressor efficiency and pump down refrigeration system.  
    • Replace dehydrator and check discharge and suction pressure.  
    — Replace compressor oil filter when refrigeration system work is performed.  
Electrical
•     Check controller for alarms.  
•     Run pretrip test.  
•     Check battery voltage.  
  • • Inspect/clean battery terminals and check electrolyte level.  
  • • Inspect wire harness for damaged wires or connections.  
    • Inspect alternator bearings and brushes.*  
    • Inspect electric motor bearings (Model 50).*  
Structural
• • • Check for oil, fuel, coolant and refrigerant leaks.  
• • • Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).  
  • • Inspect tapered roller bearing idlers for leakage and bearing wear (noise).  
  • • Check and clean evaporator and condenser coils.  
  • • Clean defrost drains.  
  • • Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.  
    • Inspect clutch.*  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Pretrip 750
Hours		 Annual/ 2,000 Hours Inspect/Service These Items Completed
Microprocessor
•     Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).  
Engine
•     Check fuel supply.  
•     Check engine oil level.  
• • • Check engine coolant level.
    Caution
  • Hazardous Pressures
  • Do not remove expansion tank cap while coolant is hot.
  
• • • Inspect belts for condition and proper tension.  
• • • Check engine oil pressure hot, on high speed.  
• • • Listen for unusual noises, vibrations, etc.  
    • Change engine oil (hot). (2000 hrs with bypass filter or synthetic oil).  
  • • Change oil filters.  
  • • Clean and service crankcase breather.  
  • • Drain water from fuel tank and check vent.  
  • • Replace fuel filter  
  • • Replace dry type air cleaner element.  
  • • Inspect/clean electric fuel pump filter.  
  • • Check air cleaner hose for damage.  
    — Check that engine coolant antifreeze protection is at –30 F (–34 C) every 1,000 hours or 6 months year (whichever occurs first).  
    — Adjust engine valve clearance every 1,000 hours.  
    • Check and adjust engine speeds.  
    • Check condition of engine mounts.  
    • Check restraining mount (snubber) pre-load adjustment.  
    — Clean and test fuel injection nozzles every 3,000 hours.  
    — Replace fuel return lines between fuel injection nozzles every 10,000 hours or sooner, as required.  
    — Change ELC (red) engine coolant every 5 years or 12,000 hours.  
Refrigeration
• • • Check refrigerant level and compressor oil condition.  
• • • Check for proper suction pressure.  
    • Check throttling valve regulating pressure on defrost.  
    • Check compressor oil level.  
    • Check compressor efficiency and pump down refrigeration system.  
    • Replace dehydrator and check discharge and suction pressure.  
    — Replace compressor oil filter when refrigeration system work is performed.  
Electrical
•     Check controller for alarms.  
•     Run pretrip test.  
•     Check battery voltage.  
  • • Inspect/clean battery terminals and check electrolyte level.  
  • • Inspect wire harness for damaged wires or connections.  
    • Inspect alternator bearings and brushes.*  
    • Inspect electric motor bearings (Model 50).*  
Structural
• • • Check for oil, fuel, coolant and refrigerant leaks.  
• • • Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).  
  • • Inspect tapered roller bearing idlers for leakage and bearing wear (noise).  
  • • Check and clean evaporator and condenser coils.  
  • • Clean defrost drains.  
  • • Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.  
    • Inspect clutch.*  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Parent topic: Unit Maintenance

Condenser Unit

Pretrip 1,200
Hours		 2,000
Hours		 Annual/ 3,000 Hours Inspect/Service These Items Completed
Microprocessor
•       Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).  
        Engine  
•       Check fuel supply.  
• •     Check engine oil level.  
• •     Check condition and tension (1,200 hrs) of belts.  
• •     Check engine oil pressure hot, on high speed.  
• • • • Listen for unusual noises, vibrations, etc.  
  •     Check air cleaner hose for damage.  
  •     Inspect and clean electric fuel pump filter.  
  •     Check engine coolant level every 1,000 hours or 6 months (whichever occurs first).  
  •     Check that engine coolant antifreeze protection is at –30 F (–34 C) every 1,000 hours or 6 months year (whichever occurs first).  
    •   Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year (whichever occurs first)  
    •   Change EMI 2000 (black) fuel filter.  
    •   Change engine oil and oil filters (hot). Requires oil with API Classification CJ-4 or CK-4 (ACEA Rating E6 for Europe) and EMI 2000 bypass oil filter.  
    •   Check restraining mount (snubber) pre-load adjustment.  
      • Drain water from fuel tank and check vent.  
      • Check and adjust engine speeds (high and low speed).  
      • Check condition of engine mounts.  
      • Test fuel injection nozzles at least every 3,000 hours. Based on EPA 40 CFR Part 89.  
      — Adjust engine valve clearance every 1,000 hours.  
      — Replace fuel return lines between fuel injection nozzles every 10,000 hours or sooner, as required.  
      — Change ELC (red) engine coolant every 5 years or 12,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank.  
Electrical
•       Check controller for alarms.  
•       Run pretrip test.  
•       Check battery voltage.  
  •     Inspect battery terminals and electrolyte level.  
  •     Inspect wire harness for damaged wires or connections.  
      • Inspect alternator bearings and brushes.*  
      • Inspect electric motor bearings (Model 50).*  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  
Refrigeration
• •     Check refrigerant level.  
  •     Check compressor oil level.  
      • Check discharge and suction pressures.  
      • Check compressor efficiency.  
      — Replace dehydrator and compressor oil filter every two (2) years.  
Structural
• •     Visually inspect unit for fluid leaks.  
• •     Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).  
  •   • Inspect clutch for shoe and anchor bushing wear with a mirror. Check bearings.*  
      • Inspect idlers and jackshaft (if so equipped) for leakage and bearing wear.*  
      • Clean entire unit including condenser coils, evaporator coils, and defrost drains.  
  • • • Check all unit, fuel tank, engine, and electric motor mounting bolts, brackets, lines, hoses, etc.  
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).  

Remote Evaporators

Pretrip 1,200 Hours Annual/ 3,000 Hours Inspect/Service These Items Completed
Electrical
  • • Inspect wire harness for damaged wires or connections.  
    • Inspect/replace DC fan motors.  
Structural
• • • Visually inspect unit for fluid leaks.  
• •   Visually inspect unit for damaged, loose or broken parts.  
  • • Clean entire unit including evaporator coils and defrost drains.  
    • Check all mounting bolts, brackets, lines, hoses, etc.  

Maintenance Inspection Schedule Checklist Authentication

Thermo King Dealership Name and Number  
Inspector / Technician’s Name  
Date Inspection Completed  
Thermo King Unit / Model  
Unit Serial Number  
Current Hour Meter Reading  

Comments: