Maintenance Inspection Schedule

Pretrip Every 1,500 Hours Every 3,000 Hours* Annual/ 4,500 Hours As Needed Inspect/Check/Service These Items
    Microprocessor:
•         Run Pretrip Test. (see Performing a Pretrip Test).
    Engine:
•         Check fuel supply.
•         Check engine oil level.
• • • •   Inspect belts for condition and proper tension.
• • • •   Check engine oil pressure hot, on high speed (should display OK).
• • • •   Listen for unusual noises, vibrations, etc.
• • • •   Check engine coolant level and antifreeze protection (-30 F [-40 C]).
  • • •   Drain water from fuel tank and check vent.
  • • •   TK486V25, TK486V25L1 and TK486VHA Engines Only: Inspect/clean electric fuel pump filter.
  • • •   TK488CR and TK488CRH Engines Only: Inspect/clean electric fuel pump prefilter screen.
  • • •   TK488CR1 and TK488CRH1 Engines Only: Inspect/clean the fuel strainer / pressure regulator assembly prefilter screen.
  • • •   TK486V25, TK486V25L1 and TK486VHA Engines Only: Check and adjust engine speeds (high and low speed).
  • • •   Check condition of drive coupling bushings.
      •   Check engine mounts for wear.
    •     Replace EMI 3000 air cleaner element (see EMI 3000 Air Cleaner) at 3,000 hours or two years (whichever occurs first). See Note.
    •     Replace EMI 3000 fuel filter/water separator. See Note.
    •    

TK488CR and TK488CRH Engines Only: Replace EMI 3000 fuel filter/water separator. See Note.


TK488CR1 and TK488CRH1 Engines Only: Replace the primary and secondary fuel filters. See Note.
        • TK488CR1 and TK488CRH1 Engines Only: Drain water separator as needed. Alarm Code 517 indicates water level high and separator needs draining.
    •     Change engine oil and oil filter (hot). Requires oil with API Classification CJ-4 or CK-4 (ACEA Rating E6 for Europe). See Note.
    •     TK 486V25, TK486VHA, TK488CR and TK488CRH Engines Only: Adjust engine valve clearance.
        • TK486V25L1, TK488CR1 and TK488CRH1 Engines Only: Adjust engine valve clearance.
    •    

TK488CR and TK488CRH Engines Built Before 2024 Engine Model Year (MY) Only:

Inspect and clean the EGR system as necessary according to the maintenance schedule, 3000 hours. When alarm code 618 is active, the engine operation will be in default running mode and be limited to low-speed and 75% maximum-available-torque only. If an EGR valve alarm code (618/ P148A) occurs on an engine with less than 3,000 total engine hours, clean the EGR valve and cooler as necessary to eliminate the alarm code.
        •

TK488CR1, TK488CRH1, TK488CRG1 Engines Before 2024 Engine Model Year (MY) Only:

Inspect and clean the EGR system, as necessary. No scheduled EGR system maintenance is required, >5000 hours or as needed. Alarm Code 570 will display when the EGR system needs cleaning. If cleaning is not completed when Code 570 is active, eventually, the EGR Valve deposit accumulation limit will be reached, and an EGR Valve Alarm Code 618 (P148A) will be set, and the engine operation will be limited to default running mode, low-speed and 75% max-available torque, only. Alarm Code 618 means that the accumulated deposit amount has exceeded the allowable limit. If Code 618 occurs on an engine with less than 5,000 total engine hours, clean the EGR Valve and Cooler as necessary to eliminate the alarm code.
    •    

TK488CRX1, TK488CRG1, TK488CRH1, TK488CR1 Engines Built 2024 and After Engine Model Year (MY) Only:

Inspect and clean the EGR system as necessary according to the maintenance schedule, 3000 hours. Alarm Code 570 will display when the EGR system needs cleaning. If cleaning is not completed when Code 570 is active, eventually, the EGR Valve deposit accumulation limit will be reached, and an EGR Valve Alarm Code 618 (P148A) will be set. When alarm code 618 is active, the engine operation will be in default running mode and be limited to low-speed and 75% maximum-available-torque only. If an EGR valve alarm code (618/ P148A) occurs on an engine with less than 3,000 total engine hours, clean the EGR valve and cooler as necessary to eliminate the alarm code.
    •     TK486V25, TK486V25L1 and TK486VHA Engines Only: Test fuel injection nozzles at least every 3,000 hours.
      —   Change ELC (red) engine coolant every 5 years or 12,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank (see Engine Cooling System).
      —   TK486V25, TK486V25L1 and TK486VHA Engines Only: Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Note Units equipped with Severe Duty Filtration Package - Replace air cleaner element, replace fuel filter/water separator, and change engine oil and oil filter every 4,000 hours.
    Electrical:
  • • •   Inspect battery terminals and electrolyte level.
  • • •   Inspect wire harness for damaged wires or connections.
  • • •   Inspect AC generator and alternator wire connections for tightness.
      •   Inspect electric motors.
      •   Inspect and, if required, re-torque all electrical connections on the contactors in the Fan Control Box to 15 in-lb (1.7 N•m).
      •   Inspect and, if required, re-torque all electrical connections on the contactors in the High Voltage Box in SmartPower units. Torque the connections on the Compressor Motor Contactor, Phase Contactors, and Overload Relay to 22 in-lb (2.5 N•m). Torque the connections on all other contactors to 15 in-lb (1.7 N•m).
    Refrigeration:
• • • •   Check refrigerant level.
  • • •   Check for proper suction pressure.
  • • •   Check compressor oil level and condition.
      •   Check compressor efficiency and pump down refrigeration system.
      •   Empty oil collection container mounted on compressor.
      —   Replace dehydrator and check discharge and suction pressure 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).
  • • •   Visually inspect the top of the unit for debris, soot build up, branches, and bird nesting material – remove debris.
  • • •   Inspect idlers for bearing wear (noise).
  • • •   Clean entire unit including condenser and evaporator coils and defrost drains.
  • • •   Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.