⚠️ DOT OUT-OF-SERVICE CRITERIA ⚠️
Any item marked as "Out of Service" violation means the vehicle MUST NOT BE OPERATED until repaired and re-inspected. Violations can result in fines up to $25,000 per offense and criminal penalties.
📋 FMCSA COMPLIANCE NOTICE: This inspection follows Federal Motor Carrier Safety Administration regulations 49 CFR Parts 393 and 396. All commercial vehicles must pass this inspection annually by a qualified inspector. Keep inspection records for at least 14 months.
Brake Systems (CFR 393.40-393.52)
Regulation: Every commercial motor vehicle must have brakes adequate to control movement and stop/hold the vehicle.
- Check brake pedal reserve - must have at least 1/5 (20%) of total travel
- Listen for air leaks with brakes applied - no audible leaks allowed
- Verify brake adjustment within manufacturer specifications
- Check brake lining/pad thickness - minimum 1/4" (6mm)
- Test air pressure build-up: 50 to 90 psi within 3 minutes
- Verify low air warning activates before 60 psi
- Check air loss rate: less than 3 psi/min single, 4 psi/min combination
- Ensure spring brakes apply between 20-45 psi
- Test parking brake holds vehicle on 20% grade
Coupling Devices (CFR 393.70)
Regulation: Coupling devices must be properly designed, maintained, and used for safe operation.
- Inspect fifth wheel plate for cracks or damage
- Check locking mechanism is secure and functioning
- Verify proper lubrication on fifth wheel plate
- Ensure no missing or damaged mounting bolts
- Check kingpin for wear or damage
- Verify safety chains/cables if equipped
Exhaust System (CFR 393.83)
Regulation: Exhaust must be secure, leak-free, and discharge away from passenger compartment.
- Check for exhaust leaks - none permitted
- Ensure exhaust discharge is not under passenger compartment
- Verify system is securely mounted with proper hangers
- Check muffler and pipes for damage or deterioration
- Ensure tailpipe extends beyond body or to rear of cab
Fuel System (CFR 393.65-393.67)
Regulation: Fuel systems must be secure, leak-free, and properly vented.
- Check entire fuel system for leaks - none permitted
- Verify fuel tank is securely mounted with proper straps
- Ensure fuel cap is present and seals properly
- Check fuel lines are protected from damage
- Verify no fuel system components are within 12" of exhaust
Lighting Devices & Reflectors (CFR 393.9-393.33)
Regulation: All required lamps must be operational whenever vehicle is operated.
- Test headlights - both high and low beams must function
- Check tail lights - both must be operational
- Verify all stop lights are functioning
- Test turn signals - front and rear, left and right
- Check clearance lamps (required on vehicles 80" wide or more)
- Verify side marker lamps (required on vehicles over 30' long)
- Ensure red reflectors on rear are clean and visible
- Check amber reflectors on sides are present
- Test 4-way hazard flashers
Steering Mechanism (CFR 393.209)
Regulation: Steering wheel lash (free play) must not exceed specified limits.
- Check steering wheel free play - max 2" for 20" wheel diameter
- Test for binding or jamming in steering system
- Verify power steering is functioning properly
- Check for loose or missing steering components
- Inspect steering column for damage or excessive wear
- Ensure steering wheel is securely attached
Suspension (CFR 393.207)
Regulation: No broken leaves in leaf springs. No broken coil springs or suspension parts.
- Inspect for broken or missing leaf springs
- Check for damaged or leaking shock absorbers
- Verify U-bolts are tight and secure
- Check air bags are properly inflated (if equipped)
- Inspect spring hangers and shackles
- Look for cracked or broken torque arms
- Ensure axle positioning parts are secure
Tires (CFR 393.75)
Regulation: Buses require 4/32" tread on front axle, 2/32" on all other positions.
- Measure front tire tread depth - minimum 4/32" required
- Check other tire positions - minimum 2/32" required
- Verify no recapped/retreaded tires on front axle
- Inspect for cuts that expose belt material
- Check tire pressure - within 10% of sidewall rating
- Look for bulges, bumps, or knots in tires
- Ensure tire sizes match on same axle
- Verify load rating adequate for vehicle weight
Wheels & Rims (CFR 393.205)
Regulation: Wheels/rims must not be cracked, broken, or have elongated bolt holes.
- Inspect wheels and rims for cracks or damage
- Verify all lug nuts are present and properly tightened
- Check for rust trails indicating loose lug nuts
- Look for bent or damaged rims
- Ensure wheels are properly aligned
- Check hub oil seals for leaks (if applicable)
Windshield & Wipers (CFR 393.60)
Regulation: Windshield must be free of damage in area swept by wipers.
- Check windshield for cracks in driver's view area
- Test wipers for proper operation
- Verify washer fluid sprays adequately
- Ensure wiper blades make full contact
- Check for discoloration or damage affecting visibility
Emergency Equipment (CFR 393.95)
Regulation: Emergency equipment must be in place and ready for use.
- Verify fire extinguisher is properly charged and mounted
- Check for three reflective triangles or approved warning devices
- Ensure spare fuses are available (if vehicle uses fuses)
- Verify first aid kit if required by company policy
- Check emergency exit operation and markings
POST-INSPECTION REQUIREMENTS:
- • Complete inspection report and file with vehicle records
- • Place OUT OF SERVICE sticker on any failed vehicle
- • Document all repairs before returning vehicle to service
- • Update inspection sticker/decal with current date
- • Submit copies to fleet manager and compliance officer