Kenworth W900 Preventive Maintenance Checklist

Follow this structured procedure to ensure comprehensive preventive maintenance of Kenworth W900 trucks.

Maintenance Schedule Intervals

Follow these recommended maintenance intervals for your Kenworth W900 to ensure optimal performance and longevity.

A Service (10,000-15,000 miles)

  • Complete oil and filter change
  • Grease all chassis points
  • Check fluid levels and top off
  • Inspect belts and hoses
  • Check tire pressure and wear
  • Perform basic safety inspection
  • Inspect air system for leaks

B Service (30,000 miles)

  • Perform all A Service items
  • Replace fuel filters
  • Service batteries and connections
  • Adjust valve lash (if needed)
  • Inspect cooling system thoroughly
  • Check driveline components
  • Inspect suspension components

C Service (60,000 miles)

  • Perform all A and B Service items
  • Replace transmission fluid
  • Replace differential oil
  • Service wheel bearings
  • Pressure test cooling system
  • Adjust clutch (if applicable)
  • Complete brake system overhaul

D Service (120,000 miles)

  • Perform all A, B, and C Service items
  • Replace coolant
  • Check engine mounts
  • Inspect turbocharger
  • Check injector performance
  • Inspect aftertreatment system
  • Complete overhead valve adjustment

Engine Maintenance Procedures

Follow these engine-specific maintenance procedures for the Kenworth W900.

Cummins Engine Maintenance

  • Check oil level using dipstick
  • Inspect air filter and housing
  • Check coolant level and condition
  • Examine fan belt tension and wear
  • Test fuel/water separator operation
  • Inspect turbocharger for leaks/damage
  • Check crankcase breather system

PACCAR Engine Maintenance

  • Verify oil level and condition
  • Inspect air intake system
  • Check coolant pH and freeze point
  • Examine belt routing and tensioner
  • Inspect cooling fan operation
  • Check electronic control module
  • Verify proper throttle response

CAT Engine Maintenance

  • Check engine oil levels
  • Inspect air cleaner restriction indicator
  • Verify coolant levels and mixture
  • Check serpentine belt condition
  • Inspect fuel system components
  • Test ACERT emissions components
  • Check engine ECM for fault codes

Engine Performance Tests

  • Perform cylinder compression test
  • Check fuel pressure at idle and load
  • Verify boost pressure readings
  • Test exhaust backpressure
  • Check engine idle stability
  • Perform loaded engine test
  • Monitor fuel consumption metrics

W900-Specific System Inspection Checklist

Verify the following components as part of your Kenworth W900 preventive maintenance program.

Drivetrain Systems

  • Inspect U-joints for wear or movement
  • Check driveshaft carrier bearings
  • Verify transmission mounts condition
  • Inspect differential oil level and quality
  • Check transmission input/output seals
  • Verify proper shifting through all gears
  • Inspect clutch free play (manual trans.)
  • Check for driveline vibration

Cooling System

  • Pressure test radiator cap
  • Inspect radiator for corrosion or debris
  • Check coolant condition with test strips
  • Verify coolant level in surge tank
  • Inspect water pump for leaks or play
  • Check fan clutch engagement
  • Examine all hoses for soft spots or cracks
  • Test thermostat operation

Fuel System

  • Replace primary fuel filter
  • Replace secondary fuel filter
  • Drain water separator
  • Check fuel lines for leaks or chafing
  • Inspect fuel tank mounting brackets
  • Clean fuel tank ventilation
  • Check fuel transfer pump operation
  • Test fuel quality (microbial contamination)

Exhaust & Emissions

  • Inspect exhaust system for leaks
  • Check DPF status and ash accumulation
  • Verify SCR system operation
  • Test DEF quality and injector function
  • Inspect exhaust manifold gaskets
  • Check EGR system components
  • Verify aftertreatment sensors
  • Inspect exhaust mounting hardware

Brake System

  • Measure brake drum/rotor dimensions
  • Check brake lining thickness
  • Verify slack adjuster travel
  • Test low air warning systems
  • Inspect brake chambers
  • Check air system for leaks
  • Test parking brake hold strength
  • Verify ABS operation and fault codes

Electrical System

  • Test battery voltage under load
  • Clean and secure battery connections
  • Check alternator output (13.8-14.2V)
  • Test starter draw and engagement
  • Verify all lights and signals
  • Inspect wiring harnesses for damage
  • Test all dash gauges and warning lights
  • Check charging system under load

W900 Chassis & Cab

  • Inspect frame rails for cracks
  • Check crossmember condition
  • Verify cab mounts and bushings
  • Lubricate door hinges and latches
  • Test HVAC system operation
  • Inspect mirrors and adjustments
  • Check windshield for cracks/chips
  • Test wiper motors and blades

Air System

  • Drain air tanks of moisture
  • Test air dryer operation
  • Check compressor cut-in/cut-out (psi)
  • Inspect air lines for wear or damage
  • Test air pressure build-up time
  • Verify air pressure leakage rate
  • Check air governor operation
  • Inspect air system safety valves
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