Why a structured PM matters for Class 7/8 trucks
Preventative maintenance isn't just about uptime - it's compliance, safety, fuel economy, and tire/brake life. TACH's PM Inspection checklist standardizes what your techs inspect and how they document findings so you catch issues early, build clean maintenance records, and move through audits with confidence.
Download the TACH PM Inspection Form (PDF) to use in your shop today.
On the checklist, certification language confirms the vehicle has passed inspection items in accordance with 49 CFR Part 396 (FMCSR) - a crucial note for audits and annual records.
What's included in the TACH PM checklist (overview)
The page-1 checklist organizes 45 inspection points into logical systems, plus a documentation section for "Failed" items, services performed, error code scans, and technician sign-off. All item numbers below match the form so your techs can follow along one-to-one.
Brakes (Items 1–5)
- Brake Pads (Front / Rear/F / Rear/R) - measure remaining life and note uneven wear
- Condition of Drum or Rotors - cracks, heat checking, scoring
- Brake Lines/Hoses - chafing, leaks, routing
- Parking Brake - apply/hold test
- Glad Hands - seals, leaks, hose wear
Air System (Items 6–9)
- Drain Air Tanks, Inspect Dryer - remove moisture; check desiccant/dryer function
- Air Compressor - performance, governor cut-in/out
- Any Leaks - audible/soapy water test where needed
- Vacuum or Hydraulic Brake System (if applicable) - integrity and operation
Exhaust System (Items 10–11)
- Any Leaks - soot tracks, damaged clamps/flex sections
- All Heat Shields - present and secure to protect lines and body
Fuel System (Items 12–16)
- Any Leaks - lines, fittings, pump area
- Filler Cap(s) Not Missing - sealing and tether
- Tank Securely Attached - straps, mounts, corrosion
- Condition of Fuel Lines - abrasion, routing, clamps
- Fuel Water Separator - drain/replace as needed
Body & Electrical (Items 17–23)
- Headlights - aim, brightness, lens condition
- Tail Lights - function and visibility
- Running Lights - clearance and marker lights
- Wipers - blade condition and operation
- Windshield / Mirrors - cracks, mounting, adjustment
- Dash Lights - gauge and warning light function
- Check Engine Lights - confirm no active fault indicators
Wheels, Rims & Tires (Items 24–29)
- Axle Seals - leaks at hubs
- Studs & Lug Nuts - damaged or missing hardware
- Wheel Bearings - play/noise
- Mud Flaps - present, secure, legal height
- Driving Tires - tread depth, irregular wear, inflation
- Steering Tires - tread depth and condition; alignment clues
Steering Mechanisms (Items 30–35)
- Steering Wheel Free Play - excessive movement check
- Steering Gear Box - mounting, leaks, operation
- Steering Shaft U-Joints - wear and looseness
- Pitman Arm - connection and movement
- King Pins, Ball & Socket Joints - wear indicators
- Tie Rods & Drag Links - check for wear/looseness, cotter pins, boots
Suspension & Alignment (Items 36–40)
- Hangers, Bushings, Pins - cracks, wear, security
- Springs, Air Bags - damage, proper inflation
- U-Bolts - Front - torque and condition
- U-Bolts - Rear - torque and condition
- Alignment (Tire Wear) - inspect wear patterns to catch geometry issues early
HVAC (Items 41–42)
- Air Conditioning - belt/pressure/vent temps
- Heater - core operation and airflow
Transmission & Clutch (Items 43–45)
- Clutch Pedal Free Travel - adjustment check
- Clutch Brake Operation - function test
- Any Transmission Grind - road test/shift quality notes
Documenting "Failed" items & corrective actions
The form provides an open field to record Failed Inspection Items with reference numbers and notes. This becomes your action list for same-day fixes or scheduled repairs and a paper trail for DOT or insurer reviews.
Best practices for documentation:
- Use item numbers for quick reference
- Note specific measurements (brake thickness, tread depth)
- Photograph critical failures
- Estimate repair urgency (immediate, next PM, monitor)
PM services you can log on the same form
Use the PM Services Completed matrix to check off maintenance performed and quantities:
- Oil Change - engine oil type and quantity
- Oil Filter(s) - number of filters replaced
- Fuel Filter(s) - number of filters replaced
- Grease / Lube - chassis points serviced
- Air Filter - primary and secondary if applicable
- Belt(s) Replaced - specify which belts
- Coolant - topped off or flushed
- Oil Full, No Leaks - final check confirmation
There's also a field for Error Code / Diagnosis Scan Completed and a box for Any Error Codes? to capture DTCs during the visit.
Technician sign-off & compliance statement
Every inspection closes with:
- Tech Name and Tech Signature for accountability
- A certification block confirming the vehicle passed inspection items in line with FMCSR 49 CFR Part 396
Maintain these forms with your maintenance files for audit readiness. Digital copies in your DMS provide searchable records for warranty claims and compliance reviews.
How to run this checklist in your shop (simple workflow)
- Identify the unit - Customer, Service Center, Unit/VIN, RO/Invoice #, Date
- Walk the systems in order (Items 1–45) - Use pass/fail boxes to speed the process and avoid misses
- Record failed items - Prioritize safety-critical repairs first
- Complete PM services - Oil, filters, grease, etc. and log quantities
- Run an error-code scan - Note any DTCs found
- Sign & certify the inspection - Attach parts/labor documentation to the RO
Time-saving tip: Pre-stage common PM parts (filters, oil, belts) based on your fleet's service intervals to reduce bay time.
Need the form? Download the printable PM Inspection checklist here.
Pro tips to maximize ROI from your PMs
- Track tire wear vs. alignment - Use Item 40 cues to adjust alignments before steer/drive tires scallop
- Drain air tanks routinely (Item 6) - Protects valves, chambers, and dryer media
- Bundle PM services - Combine filters, grease, and a quick code scan to minimize downtime
- Standardize torque logs - After wheel/tire work (Items 24–29)
- Photo-document failures and fixes - For warranty and claim support
- Use oil analysis - Extend drain intervals safely on proven engines
- Schedule PMs during slow periods - Avoid peak freight seasons
Frequently Asked Questions
How often should I run a full PM?
Follow your OEM guidance and duty cycle. Many long-haul fleets run PM-A every 15K–25K miles (or ~250 engine hours), with deeper PM-B/C at wider intervals. Use fluid analysis and tire/air-system findings to fine-tune.
Does this checklist help with FMCSR compliance?
Yes. The form's certification references 49 CFR Part 396, and the system-by-system approach supports your annual inspection evidence. Keep signed copies with ROs.
What should I do with "Failed" items?
Record the item number(s), document the condition, and schedule immediate or next-available repairs. Attach parts/labor invoices to the same RO for a complete history.
Can I add tire brand programs to PM?
Absolutely. During Items 28–29 & 40, log tread depths and rotations. If you're a TACH member, ask about our tire partnerships to reduce cost per mile on replacement programs.
How does TACH help with PM compliance and costs?
TACH provides cash advances for preventative maintenance, helping you avoid costly emergency repairs. Our network of service partners offers member discounts on parts and labor. Plus, our expense tracking helps you monitor PM costs and identify savings opportunities.
The bottom line
A disciplined PM process catches small issues before they cascade into roadside events. Use this 45-point checklist, log your services and code scans, and close with tech certification to stay audit-ready and road-ready.
Download the PM Inspection Form and start using it in your shop today.
Ready to reduce your maintenance costs? TACH members get access to discounted parts through our service network, cash advances for scheduled maintenance, and expense tracking to monitor your PM spend. Join TACH today to keep your trucks running and your costs down.
If you want this checklist embedded into your shop SOPs, TACH can brand it for your fleet and add digital fields for automated recordkeeping. Contact our fleet support team to learn more.
