Inspection Form: Vehicles A. Engine Operation Materials: Tool to remove battery covers Tool to remove engine splash guards Can of dry solvent-type lubricant Rag Flashlight Has the vehicle s exterior been washed? Wash interior of waste truck bed Target time: 8 to 12 minutes, plus 15 minutes to wash the engine 1) When approaching vehicle, check for leaks. Check steps and grab handles before entering cab. Check door, door rubber, latches locks etc. Fasten seat belt. Check seat adjustment mechanisms and seat cover. 2) Check ignition switch operation for loose or rough action and return from starting position. Check key tumblers for needed repairs or if worn schedule for replacement. 3) If equipped with air brakes, bleed the air down, hold foot on the brake pedal for 15 seconds and see if there is any movement of either air gauge. Continue bleeding the brakes down until the warning buzzers sound to make sure they work. 4) When placing foot on the clutch, check for top clearance. If this is a hydraulic clutch unit, you should be able to feel the two different linkages as the free play is used up. Inspect pedal pads for side play, travel and wear.
5) With vehicle out of gear, clutch pedal depressed and transmission in neutral, check starter action and disengagement. Check voltmeter. If equipped, should not read less than 9.5 volts while cranking, depending on outside temperature. 6) Check clutch disengagement - with engine running, push clutch pedal to floor and shift into gear - check operation of clutch brake, if equipped, at what position does clutch engage? 7) Check oil pressure and listen to engine operation - noise, idle, misfire, smoke, valves, etc. Check air pressure build up. 10 lbs per minute. Inspect instrument gauges for response - note charging amps, Check charging amps with all lights on. Should be charging, If volt meter equipped, vehicle should be charging at 14.4 to 14.8 volts. On an air-braked vehicle, the air pressure will take a few minutes to build. While this air pressure is building, check the following items. On a non-air-braked vehicle, turn these accessories on while driving into or to the shop. 8) Horn operation check. In different wheel positions. Test both electrical and air horns. 9) Steering action, play should not exceed approximately 2 inches depending on diameter. 10) Windshield, side vent glass, and rear window for cracks and clarity. Windshield washer, windshield wiper. Do they need replacing? 11) Heater and defroster operation - noise, switch operation and output. Amp gauge for excess draw and alternator output. Air conditioning operation. To inspection area on A and B; to wash area on C - check the following, shift the transmission through the shift pattern (if practical.) Check for speedometer response. 12) Brake performance (do brakes lock up evenly?) Parking brake performance.
13) Shut down engine - unlatch cab lock, if so equipped. Exit cab, hang any hoses out of way and remove battery box covers - unlatch and tilt cab - set safety latch. Unhook any engine splash guards. Clean engine, accessories, and chassis with power washer. Drive to inspection area. 14) Leave engine running in neutral. Put tractor trailer protection valve in operating position (if equipped). Bleed air down by using foot valve - note pressure at governor cut-in (minimum 70 psi). Continue bleeding air down and note pressure when low air buzzer sounds. Note pressure when protection control valve sets. Lube hand throttle and set engine at fast idle. Unless checked previously when vehicle was started, build air pressure up. 15) Registration and permits. Emergency and safety equipment, condition of cab headliner, sun visors and overhead vent-lube, return throttle to idle position. 16) Check engine shutdown - lube - be sure shutdown is left in stop position. Check cab latch, if any, for adjustment - lube and leave unlatched. Fill out PMI form and repair order as needed. 17) Check mirrors and all lights from driver s seat using convex mirrors - check all circuits shown on list. Check operation of courtesy and dimmer switches and high beam indicator light, Check operation of mirror heater switch. If equipped, remove Ignition key. Check air pressure and exit cab. Additions to a school bus and RTD bus 18) Check the first aid kit for security and completeness 19) Check the seats for security, tears and dirt 20) Check emergency exits, windows, lights, floor
21) Operate and check any wheel chair lifts etc. 22) Operate the controls before entering the shop building, make sure all hydraulic controls are operating and the hydraulic units are responsive. B. Walk Around Materials: Tire pressure gauge and tread depth gauge Screwdrivers - phillips and standard Light circuit checker 3-foot stepladder where applicable Flashlight Tire square or caliper 23) Return to left side of vehicle. Inspect left door (or door on busses) weather stripping for condition - inspect hinge and lube. Check stripping. Key slot for rust. Schedule corrosion protection application if rusty. 24) Inspect left window regulator for proper operation - check condition of window channel. If rusty schedule removal and corrosion resistance application. 25) Inspect condition of cab floor for rust. Coat the floor with undercoating where necessary. Inspect floor mats. Remove floor mats if fibrous. Check under-dash wiring and air lines for secure mounting, chafing and routing and dimmer switch if on the floor. Check pedal shaft side play - brake, clutch and accelerator, check treadle valve, pin and roller lube
26) Inspect left windshield wiper motor for secure mounting and air line connections - lube. Electric motor; inspect cams and contacts. 27) Inspect windshield washer tank (if in cab), fill if necessary. Inspect seat, mounting, belts, upholstery and runners lube. C. Tire Check Inspect all tires as you perform the cab and body walk-around inspection. The tires are checked for inflation and recorded on the PMI form. If any tire is below 20% under inflation, it will be replaced following inspection. Tires are replaced if they are below 4/32nds front and 3/32nds rear on over-the-road units and 3/32nds all the way around on local units. Tires will be checked for matching. Using a straight-edge, or tire square, all dual tire axles will be measured. Any tire 1/8 of an inch larger or smaller will be removed and a matching tire installed at the end of the inspection process. All tires are inspected for cuts, exposed cord, sidewall damage, wear patterns that would indicate out-of-alignment condition. If there is unusual wear, the alignment will be checked. All wheel nuts will be checked for looseness. If any rust appears around wheel studs, tighten and torque the wheels. On spoke wheels spin the tire and look for wheel run out. It should be perfect. Install missing valve caps and if the tires are tube-type, make sure there are stem locking devices installed. Check all hubs for oil and condition. See if there are any metal flakes in the oil. If so, schedule the vehicle for wheel pull. If the oil is low, see where the leak is. If the leak is in the seal, note it on the repair order and pull the wheels and replace any bad bearings at the conclusion of this inspection. 28) Inspect windshield wiper arms for spring tension and the blade for mounting and wear. Inspect condition of grill and front of cab. Lenses and reflectors for secure mounting and condition, bumper and license plate for damage and tightness. Inspect road lights and guards for condition and mounting. Check wiring connections. All should be heat shrink tubing. 29) Inspect right side vehicle same as left, including signal light, door, glass floor and mats, wiper motor, heater and seat. Raise cab, if necessary for alternator checks - set safety latch.
30) Inspect fuel tanks and vent - fuel tank cap - threads, chain and plugs note fuel for gauge accuracy. Drain all air tanks. Inspect mud flaps for mounting and condition. Inspect side of body including lights and reflectors. Inspect rear license plates and light assembly for secure mounting, proper splices and protection. Inspect tail and stop light lenses and mounting and wiring connections. All wire splices to be protected by heat shrink tubing. Inspect and lubricate rear door where applicable. Inspect Left fuel tank and cap same as right. Inspect left side of body for lights, reflectors damage. Return tools and equipment to proper place. Add-on Van Bodies 31) Inspect interior of vehicle (back doors) where applicable. Look for ceiling, walls, or floor looseness, leaks, damage, etc. 32) Operate lift gate, lubricate 33) On dump bodies inspect, tailgate, chains, overload boards, rams, hydraulic lines, tanks, caps, vents and other mounted equipment. Add-on Waste Trucks 34) External fire extinguisher mounting. 35) Front forks, hydraulic lines, rams, leaks, mounting. 36) Inspection doors, unloading rams, slides. 37) Hydraulic fluid, tank, hoses, caps, meter. 38) Hydraulic pumps, lines, controls, mounting
39) On roll: roll units, cable, shivs, rams, lines, tanks, caps, mounting. 40) On rear: rams, plates, hoppers, loaders, compaction 41) On side loaders, tracks, rams, arms, doors, etc. Add-on for Bucket Trucks 42) Turntable, booms, cables, controls, bucket, hydraulic lines, rams 43) Tool doors equipment, etc. Add-on for Coaches 44) Evaporator fan, lines, electrical controls 45) Motor brushes, inspect and replace where necessary Add-on for Tractors Materials: Fifth wheel checker where applicable Tools to adjust fifth wheel Proceed to vehicle and install fifth wheel checker. Inspect fifth wheel mounting, latching mechanism jaws, release lever, bushings, ground strap. Check for play in fifth wheel - adjust if necessary. Return fifth wheel tools - fill out PMI form and repair order as needed.
46) Step up on catwalk - inspect condition of air hoses and hanger (If equipped). Inspect Glad hands, seals and holders. Inspect light cord for cuts and chafing check for proper mounting or spring and retainers - check for corrosion at terminal ends and condition - install plug in light circuit checker receptacle, Enter cab - note air pressure bleed-down (air pressure should not drop off more than 2 psi minute with brakes disengaged and 3 psi per minute with brakes engaged.) Check rear window molding for proper fit - check back of cab for condition and damage. Inspect step and grab handles for secure mounting. 47) Lube fifth wheel. D. Battery and Electrical Inspection Materials: fifth wheel checker where applicable battery pliers battery cable puller clamp battery terminal and cable cleaner wire brush battery box undercoating tools to remove battery hold-downs alternator/regulator tester indication gauge remote starter switch battery hydrometer if applicable load tester battery water and filler Perform with walk-around inspection or under-hood inspection wherever applicable Place tools and gauges in tote tray or use PMI roll-around. 48) Test specific gravity of batteries, (where applicable) using battery hydrometer test and record cell range. Test total battery voltage of batteries under load. Load should not exceed specific vehicle specifications. Correct battery water level
49) Inspect battery cables and connections for corrosion, chafing, bare wires and routing - replace battery box cover. Test voltage drop between battery and starter - correct if drop exceeds.3 volts. Test both positive and negative side. Check the cold cranking amps listed on the side of the battery. Divide that by 2 and adjust the amperage draw through the tester to that figure for 15 seconds. At the end of the 15 seconds see if there is smoke coming out of any of the vents in the battery. If there is not, repeat the 15 second test. The voltage should be about 9.5 volts depending on the temperature of the battery during the test. If the battery does not pass the test, then the battery should be removed and fully charged and re-checked. Remove, clean and inspect battery cables (take the dirtiest side every inspection unless both sides are dirty. E. Under Vehicle Inspection and Lube Materials: leverage bar tools to adjust brakes tools to adjust clutch tools to remove transmission and differential filler plugs tool to remove steering gear filter oil can with dry lube rags place tools on bottom of creeper seat and place near front wheel socket and breaker bar Materials: creeper drop light air hose grease gun oil drain pan (on gas units) air hose grease gun oil drain pan (on gas units) 20 minutes to 35 for trucks depending on axles, sizes and whether an oil change is performed. Raise vehicle and place on stands - place stands under axles leaving spring U-bolts accessible. Set up creeper, drop light and air hose at left front wheel. Set wheel chocks and release parking brake, raise cab or hood, if not raised for alternator check. Set safety latch and remove engine splash guards, if not removed earlier.
50) Check king pin play (maximum tolerance is 5/16 inch measured at the tire on 1100X22.5) 3/16 inch below smaller. 51) Check wheel balance. Spin wheel around to see if it returns to heavy point. 52) Adjust brakes (unless wheels are to be removed). Inspect brake return springs and retaining pins (if open from back). Inspect anchor pins for wear. Inspect wheel cylinders for leaks. Inspect backing plate for looseness and damage. If applicable, inspect brake chamber and mounting inspect scam for wear. Should only be replaced if bearing indicates play. Inspect brake hose and connections for routing, chafing, leaks. Inspect shock, check for leaks and mounting. 53) Set up grease gun and drain pan if needed, behind front wheel. Condition of wiring and looms in area of wheel well. Air lines and fittings for routing, chafing and damage. 54) Junction block for mounting and condition. Steering gear for secure mounting and condition of U-joints - lube - check and correct steering gear fluid level.
E. Under Vehicle Inspection and Lube (Continued) LUBRICATE AS YOU GO. Pitman arm for mounting and damage, drag link for mounting and damage. Drag links are replaced when they have side play - not just when they are loose. Steering arm for mounting and damage. Check steering stop for adjustment. Spring pins, bushings, shackles and brackets for wear and secure mounting. Shackles will be re-bushed and repinned if movement exceeds 1/8 inch. Spring for broken leaves and alignment - inspect rubber frame bumper. Rebound clips for proper mounting. Center bolt. U-bolts and saddles for tightness. Saddles and tighten U-bolts 375 ft. lb. or so, when rust appears at saddle. Slack adjuster, brake cam and clevis pin - lube. 55) Front cross member and frame rails for cracks, mounting, corrosion and damage. Front axle - check for damage and shifted condition. Lower radiator mounting for security and cracks. Check underside of engine for leaks and damage. Engine mounts for cracks and secure mounting. Quick release valve, mounting and lines. Oil cooler and connections for leaks. Engine mounts for cracks and secure mounting. Quick release valve, mounting and lines, oil cooler and connections for leaks. Right front same as left front clutch master cylinder for secure mounting and leaks - adjust, if necessary, mechanical clutch linkage for secure mounting - adjust, if necessary. 56) Drain oil in conjunction with schedule (if F.L.O.C.S. is equipped, perform later.) 57) Remove and inspect clutch inspection cover. Linkage for alignment, wear and cable end boots - lube threads. Clutch master cylinder for secure mounting and leaks, adjust if necessary, Clutch slave cylinder for secure mounting and leaks, adjust if necessary, mechanical clutch linkage for secure mounting, adjust if necessary. Return spring for wear and proper tension.
58) Yokes and splines for wear and looseness. Flange bolts for looseness. Universal joints for wear - lube. Center bearing for wear, loose and cracked mounting. Drive shaft guards for secure mounting. Drive shaft cross alignment. Drive shaft for parallel inputs with square. Test for drive shaft angularity equality 59) Inspect rear spring and pads for broken leaves and alignment Inspect rebound clips for proper mounting. Inspect center bolt. Inspect U-bolts and saddles for tightness. Inspect brake chambers and mountings. Inspect slack adjuster, brake cam and clevis pin - lube. Adjust brakes unless wheels are to be pulled. Inspect brake components for damage and loose bolts. Inspect brake lines and connections for leaks, routing and chafing. Inspect all electrical lines. Inspect anti-skid device, if applicable.
60) Check fluid level of rear end. Inspect underside of fifth wheel for wear and damage. Inspect differential breather - clean. Inspect differential for leaks and loose bolts. Inspect axle housing for damage and leaks. Complete inspection on right side same as left side. Leave creeper seat with tools at right rear wheel. Change rear end filter where applicable. Drain rear end, unless equipped with synthetic oils. Return all tools and equipment to proper place. F. Engine Inspection Materials: stethoscope cooling system pressure tester tools to adjust fan belts screwdriver coolant tester drop light oil can tool to remove water and/ or fuel filters timing light, (tach dwell) for non-transistorized rig Place tools in tote tray and return to vehicle Replace drain plug, oil filters and fill crankcase to full. Replace batteries and covers (if housing were painted) return battery tools 61) Inspect and replace water filter if necessary - check for leaks and secure mounting
62) Inspect coolant level - test degree of protection - fill to proper level. Inspect and pressure test radiator cap, if there are signs of leaks, Install pressure tester on radiator - do not exceed manufacturer s specifications - inspect for coolant leaks. Inspect hoses and clamps for routing and deterioration. Inspect radiator core, fins and tanks. Upper radiator mountings. Radiator shroud for condition and mounting. Water manifold for cracks 63) Fan belts - adjust if necessary. Use gauge or 15# pressure. Should deflect 3/8th inch in 12 inch span, on narrow belts, use mfg recommendation on serpentine belts. Inspect fan belts for proper belts and deterioration. Inspect fan assembly for loose blades and pulley for alignment. Water pump, pulley and bearing - check for leaks, pulley side play and rough bearings. Alternator, pulley and bearings - check pulley alignment, rough bearings, secure mounting, wiring and connections. Vibration damper for play and alignment. Power steering pump - check for leaks, secure mounting and pulley alignment - check and correct fluid level. 64) Inspect air compressor for oil leaks and mounting. Clean or replace air compressor filter. Inspect alcohol evaporator, if equipped - check for leaks and mounting fill if necessary. Note any pressure loss on radiator before removing pressure tester. 65) Inspect complete air cleaner assembly - start at top bonnet, stack, filter chamber, element. Attach quick disconnect restriction gauge and test. On diesel, with blower vacuum, should not exceed 15 inches of water. Inspect turbocharger mounting and connections.
66) Remove turbo and replace bearings and seals. Inspect crankcase ventilation. 67) Replace fuel filters in accordance with schedules. Inspect and check operation of fuel priming pump. Inspect fuel pump for leaks and secure mounting. Inspect governor seal. Inspect injector lines for routing and leaks. Make sure they are tight. Inspect throttle control linkage for proper mounting - lube 68) Inspect engine stop cable for routing and secure mounting - lube. Inspect exhaust manifold for cracks, loose bolts and leaks. Inspect exhaust flange for looseness and leaks. 69) Remove injectors and replace tips on Cummins, Cat, Detroit, test only on Mack. See manuals on others. 70) Remove, clean and inspect distributor cap - check for cracks and condition of contacts. 71) Test spark plugs and wires for power required under load. Install necessary ignition parts. Inspect ignition wiring for routing, condition and chafing. Scribe front tires if there are signs of scuffing.
72) Open drain valve on wet tank and bleed air off. Check dry tank to insure proper operation of check valve continue draining dry tank until brakes are applied. Inspect moisture ejection valve for secure mounting and evidence of proper operation. Remove jack stands - put jacks and stands away. Start engine - build up air pressure. If oil was changed, bleed oil filter. If tires show signs of feather edge, move vehicle back ten feet and bring forward again - check toe in (0 inches on radial tires - 1/16 to 1/8 inches toe-in on bias ply tires.) G. Road Test Inspection Many fleets do not road test units. If you are road testing units, have goals in mind. The fleets that do not road test have found that little, if anything, comes to light as a result of the road test. 73) Check speedometer operation. 74) Check oil pressure at idle and cruising. 75) Check maximum governed RPM noting reading on unit tachometer. 76) Return vehicle to proper location. 77) Remove tach card, check for proper reading and turn in with PMI sheet and repair order or unload electronic tach to see if its working properly.
Notes About Fleet University Fleet University Program is the home of free, valuable resources that make any fleetmanagement more productive. These materials are based on the best practices that Ron Turley developed while saving UPS nearly $100 million during five years as their national director of maintenance in the 1970s. Adjusted for inflation, that figure would be over $300 million today. Ron had one of the first authoritative voices in the fleet management industry, and his influence continues today. Following UPS, he consulted with over 170 organizations in the U.S., Canada, the Caribbean, Far East, Europe and South America. His best practices became the foundation of RTA Fleet Management Software over 35 years ago. Fleet University continues in the same spirit of improving productivity through attention to details and data, regardless of what software a fleet manager uses. Discover more resources from Fleet University at RTAfleet.com/fleetuniversity. Fleet University is presented by Ron Turley Associates, Inc. All rights reserved. 17437 N. 71st Drive, Suite 110 Glendale, AZ 85308 Phone: 800-279-0549 rtafleet.com rtafleet@rtafleet.com