7 Errors in Refrigerated Truck Maintenance and Their Fixes

Refrigerated trucks, or reefers, are essential for transporting temperature-sensitive goods across Texas and beyond. A well-maintained reefer ensures cargo stays at the correct temperature, preventing spoilage and financial losses. However, common maintenance mistakes can lead to costly breakdowns and inefficient cooling performance.

Here are seven frequent maintenance errors and tips from our team at Integrity Fleet Services on how to fix them to keep your reefer in top condition.

1. Skipping Pre-Trip Inspections

One of the biggest mistakes truck operators make is neglecting pre-trip inspections. Without a thorough check, issues like refrigerant leaks, sensor malfunctions, or worn belts may go unnoticed until it's too late.

Fix

Before every haul, perform a pre-trip reefer inspection, checking:

• Refrigerant levels for possible leaks
• Battery voltage and wiring connections
• Condenser and evaporator airflow (remove debris and obstructions)
• Door seals for cracks or leaks
• Controller settings to confirm proper temperature regulation

By addressing small issues early, you can prevent major failures on the road.

2. Running with Low Refrigerant Levels

Refrigeration units rely on a consistent refrigerant charge to maintain cooling efficiency. If the system runs low on refrigerant, the compressor has to work harder, leading to higher fuel consumption and potential failure.

Fix

• Routinely check refrigerant levels and top off when necessary.
• If refrigerant levels drop quickly, inspect for hose, compressor, or evaporator leaks.
• Use an electronic leak detector to identify hidden leaks before they worsen.

Proper refrigerant maintenance helps extend compressor life and improve efficiency.

3. Ignoring Airflow and Ventilation Issues

Blocked airflow causes temperature fluctuations, leading to hot spots that can spoil cargo. Poor ventilation is often caused by:

• Dirty evaporator coils
• Blocked return air ducts
• Improper cargo loading

Fix

• Clean evaporator and condenser coils regularly to prevent dirt buildup.
• Load cargo properly—never block airflow vents.
• Check air ducts for damage or obstructions that reduce circulation.

Maintaining proper airflow ensures even cooling throughout the reefer.

4. Overlooking Door Seal Maintenance

Worn-out door seals (gaskets) allow warm air to enter, making the cooling system overwork and causing temperature inconsistencies.

Fix

• Inspect door seals for cracks, gaps, or excessive wear.
• Replace damaged gaskets immediately to maintain an airtight seal.
• Perform the dollar bill test: Close a dollar bill in the door, then pull it out. If it slides easily, the seal isn’t tight enough and should be replaced.

A well-sealed door reduces fuel consumption and enhances cooling efficiency.

5. Failing to Maintain the Electrical System

The reefer unit relies on battery power and an intact electrical system to function properly. A weak battery or corroded wiring can result in a cooling failure mid-trip.

Fix

• Check battery voltage before every trip (it should read 12.7V when fully charged).
• Inspect all wiring connections for corrosion, looseness, or damage.
• Ensure the alternator and charging system are functioning properly.

By maintaining the electrical system, you reduce the risk of unexpected failures.

6. Skipping Oil and Filter Changes

Just like a diesel engine, reefer compressors require regular oil and filter changes. Dirty oil causes excessive wear, leading to premature compressor failure.

Fix

• Follow manufacturer guidelines for oil change intervals.
• Use the correct oil type and viscosity for your reefer unit.
• Replace fuel, oil, and air filters at the recommended intervals.

Routine maintenance extends the life of key components and improves cooling performance.

7. Ignoring Error Codes and Alarms

Modern reefer units come with diagnostic systems that alert drivers to problems via error codes or warning lights. Ignoring these alerts can turn a minor issue into a catastrophic failure.

Fix

• Never ignore a warning alarm—check and address issues immediately.
• Refer to the reefer unit’s manual for troubleshooting common error codes.
• If an issue persists, seek professional diagnostics and repairs.

Proactive troubleshooting prevents costly downtime and cargo loss.

Final Reflections

Proper refrigerated truck maintenance is essential for protecting perishable cargo, reducing repair costs, and maximizing fuel efficiency. By avoiding these seven common mistakes and following the recommended fixes, you can ensure your reefer operates smoothly and reliably on Texas highways.