Drivers, technicians, and operations managers who run heavy-duty trucks in cold or snowy regions often face the same issues every winter: fuel gelling, discharged batteries, and loss of traction on icy roads. These problems do more than disrupt schedules—they put safety, uptime, and operating costs at risk.
This guide presents winter maintenance standards that are widely applicable across markets, together with practical checklists that can be used directly in day-to-day operations. It brings together the key elements needed to build winter operations that do not stop when temperatures drop.
What you will learn in this guide
- Winter maintenance standards and priorities that are applicable globally
- Practical checklists and scheduling methods that can be implemented immediately in the field
Who this guide is for
- Drivers and maintenance technicians operating heavy-duty trucks in cold or snow-covered regions
- Operations managers and Fleet Management professionals who need to balance safety and efficiency
- Logistics and transport professionals responsible for global operations or mixed, multinational fleets
Importance of winter maintenance for heavy-duty trucks
Winter-related failures are more than occasional inconveniences. In North America, the logistics industry reports annual losses of several billion dollars caused by cold-weather disruptions. These issues underscore how severely low temperatures can affect vehicle performance, safety, and operating efficiency.
Effects of low temperatures on heavy-duty truck systems
When temperatures fall below freezing, engine oil thickens and increases resistance during startup. Diesel fuel begins forming paraffin crystals, which can clog fuel lines and restrict flow. Battery output may drop to less than half of its normal capacity, placing additional strain on starting systems. These combined factors make trucks far more vulnerable during winter operations.
Fundamental principles of winter maintenance
Winter maintenance is guided by three core principles: preventive preparation, adaptation to environmental conditions, and ensuring safety. These principles align with ISO maintenance standards and internationally recognized approaches to Predictive Maintenance. Applying them consistently helps fleets maintain reliable performance throughout the cold season.
Tire selection and traction management for winter operations
Loss of traction accounts for a considerable share of winter accidents involving heavy-duty trucks. Proper tire selection and correct use of tire chains are central to maintaining stability on icy and snow-covered roads.
Selection and inspection of studless tires
Studless tires offer enhanced grip on icy and snowy surfaces. When temperatures consistently fall below 5°C, switching to winter tires is recommended. Maintain a minimum tread depth of 4 mm and check tire pressure at least once a week to ensure optimal performance.
Procedures for installing tire chains
Metal chains provide strong durability, while resin chains offer quieter operation and easier installation. After installing chains, drive 50–100 meters and recheck for any looseness. Observe posted speed limits—typically between 30 and 50 km/h—when driving with chains.
Winter maintenance for fuel and cooling systems
Fuel gelling and cooling-system failures are among the most common causes of cold-weather starting issues. Maintaining an engine environment that performs reliably in low temperatures requires careful preparation of both systems.
Preventing fuel gelling and switching to winter-grade diesel
Once temperatures drop below −5°C, paraffin crystals begin forming in diesel fuel, restricting flow through the fuel lines. Start switching to winter-grade diesel when ambient temperatures approach 10°C. Keeping the fuel tank at least half full helps reduce condensation and prevents moisture accumulation that can lead to freezing.
Anti-freeze measures for coolant and washer fluid
A coolant concentration capable of protecting down to −35°C—typically achieved with an ethylene glycol content of 50–60%—is recommended for winter operation. Washer fluid should also be replaced with cold-climate formulations rated for −30°C to −40°C. Avoid mixing different types of fluid, as this may reduce overall performance and freeze protection.
Electrical system and battery maintenance for cold-weather operation
Batteries are particularly susceptible to performance loss in low temperatures. At −18°C, capacity may drop to roughly half of normal levels, while the power required for engine startup nearly doubles. Although typical battery life ranges from three to five years, deterioration progresses faster in cold regions.
Before winter, test battery voltage and capacity using a battery tester. Inspect terminals for corrosion or looseness, and remove any white powder-like buildup with a brush. In extremely cold regions, installing a battery heater or block heater provides an additional safeguard against cold-related failures.
Freeze-prevention measures for brake and drivetrain systems
Low temperatures can cause moisture inside air brake systems to freeze, which may reduce braking force or result in complete brake failure. Preventive measures are essential to ensure reliable operation throughout winter.
Moisture management in air brake systems
Water within compressed air can freeze and block airflow, impairing braking performance. Regularly verify that the air dryer is functioning properly, and drain accumulated moisture from the air tank using the drain valve. In colder regions, draining the system daily is recommended.
Correct use of differential locks in winter conditions
The differential lock provides effective traction support when a truck becomes stuck on snow or ice. However, improper use can damage the drivetrain. Use the differential lock only when starting from a stop or when attempting to escape low-speed slip conditions. Always disengage it during normal driving or when operating on paved roads.
Engine oil selection and warm-up procedures for winter conditions
Smooth engine starts in winter depend on choosing the right oil and applying appropriate warm-up practices. Protecting fuel efficiency and engine durability begins with daily decisions that help the vehicle perform reliably in cold weather.
Appropriate oil viscosity for winter operation
Low-viscosity oils such as 0W-30 or 5W-30 (SAE standard) maintain fluidity in low temperatures and reduce the load on the engine during startup. Replace oil before winter begins, and in cold regions, consider changing it every 10,000 to 15,000 kilometers.
Recommended warm-up practices
Extended idling wastes fuel and contributes to carbon buildup inside the engine. For modern trucks, a warm-up period of around 2–3 minutes after startup is sufficient. After that, begin driving under low load so the engine can reach operating temperature naturally during the first part of the trip.
Cabin visibility and comfort preparation for winter driving
Clear visibility and a comfortable cabin environment contribute directly to safe driving and steady decision-making. Before winter, confirm that the heater operates correctly and check for uneven temperature distribution or unusual noises. A clogged air-conditioning filter reduces heating efficiency, so clean or replace it as needed. Snow-resistant wiper blades should be installed before winter in regions where ice and snow are common.
Emergency preparedness and safety equipment for winter conditions
Breakdowns and blizzards can occur without warning during winter operations. Carry essential items such as winter clothing, blankets, a shovel, tow ropes, traction sand, a flashlight, portable power supplies, emergency tools, and drinking water.
If a truck becomes stranded in a snowstorm, keeping the exhaust outlet clear is critical. When the muffler is blocked by snow, exhaust gases can flow back into the cabin, creating a risk of carbon monoxide poisoning.
Practical schedules and maintenance checklists for winter operations
Preventing winter-related failures requires phased measures based on ambient temperature. The following schedules and checklists can be used directly in daily operations.
Inspection schedules based on ambient temperature
During the pre-winter phase (around 5°C), confirm readiness for winter tires, check and adjust coolant concentration, perform a battery load test, and inspect the fuel system.
In high-winter conditions (0°C to −10°C), complete the switch to winter-grade fuel, increase the frequency of air brake draining, and review warm-up procedures.
Daily, weekly, and monthly maintenance routines
Daily inspections include checking tire pressure and external condition, cleaning lights and mirrors, confirming washer fluid and fuel levels, visually inspecting battery terminals, and draining moisture from the air tank.
Weekly inspections cover checking oil level and color, as well as confirming coolant levels.
Monthly inspections include measuring battery voltage and conducting a comprehensive check of the brake system.
Conclusion: Establishing reliable winter operations through consistent maintenance
Three principles are essential for operating heavy-duty trucks during winter: early action, clear visibility of vehicle condition, and habitual maintenance. Approximately 70% of winter-related issues are attributed to insufficient inspections, underscoring the importance of preparation and daily routines. Maintenance should be regarded not as a cost, but as an investment that protects safety and builds trust.
Use the checklists and schedules introduced in this guide to support your winter operations starting today. Reliable winter performance begins with the maintenance you carry out now.
