Because the following regulations change frequently, you are encouraged to check the following website for the most current information. www.fmcsa.dot.gov/documents/08-cargotankbulkpkg.pdf. Vehicle Care and Maintenance The Office of Motor Carriers has determined that mechanical deficiencies are often a contributing factor in accidents involving commercial motor vehicles. It has also been well-documented that DOT roadside inspections uncover mechanical deficiencies that are often serious enough to result in declaring the vehicle to be out-of-service. Inspections and preventive maintenance programs must be an integral part of your safety program. The implementation of a sound and effective inspection and maintenance program will keep unsafe motor vehicles off the roadways and help prevent accidents, injuries, and fatalities associated with operating defective equipment. In general, all carriers who are engaged in interstate and intrastate transportation are required to: systematically inspect, repair, and maintain, or cause to be systematically inspected, repaired, and maintained, all vehicles subject to its control. The regulations not only specify the inspections and maintenance that shall be carried out on vehicles, it also forbids the operation of motor vehicles found by inspection or operation to be defective. This prohibition includes vehicles that are in route and allows their continued operation ONLY to the nearest place where repairs can safely be effected. Such operation may be conducted only if it is less of a danger to public safety than it would be to allow the vehicle to remain at the side of the highway. Illustrations of the various types of report forms are presented on the following pages. These illustrations are photocopied from J. J. Keller & Associates, Inc. Motor Carrier Safety Report. Their use without the written consent of J. J. Keller & Associates, Inc. is discouraged. CPM0611 1
VEHICLE GROUPS ESTABLISHED BY FHWA (SECTION 383.91) Group: A Combination Vehicle B Heavy Straight Vehicle C Small Vehicle Description: Any combination of vehicles with a GCWR of 26,001 or more pounds provided the GVWR of the vehicle(s) being towed is in excess of 10,000 pounds. (Holders of a Group A license may, with any appropriate endorsements, operate all vehicles within Groups B and C.) Any single vehicle with a GVWR of 26,001 or more pounds, or any such vehicle towing a vehicle not in excess of 10,000 pounds GVWR. (Holders of a Group B license may, with any appropriate endorsements, operate all vehicles within Group C.) Any single vehicle, or combination of vehicles, that does not meet the definition of Group A or Group B as contained herein, but that either is designed to transport 16 or more passengers including the driver, or is placarded for hazardous materials. Endorsements: 1. Double/triple trailers ( T ); 2. Passenger vehicles ( P ); 3. Tank vehicles ( N ); or 4. Required to be placarded for hazardous materials ( H ); and, 5. Air brake restrictions ( L ). AGE REQUIRMENTS: Intrastate Interstate Class A 18 ** 21 Class B 18 ** 21 Class C 16 ** 21 ** Must be 21 years of age. CPM0611 2
Inspection, Repair, and Maintenance Every motor carrier shall systematically inspect, repair, and maintain, or cause to be systematically inspected, repaired, and maintained, all motor vehicles subject to its control according to Section 396.3(a) of the Federal Motor Carrier Safety Regulations. In addition there are certain records which must be maintained for all vehicles controlled for 30 consecutive days or more [396.3(b)]. Required Records. 1. An identification of the vehicle including must be on outside of file folder for each vehicle a. Company number b. Make c. Serial number d. Year e. Tire size f. Description of vehicle g. Photo of vehicle (Optional, but a good method of identification) h. A DOT specification cargo tank requires a birth certificate (If vehicle is not owned by the motor carrier, the record shall identify the name of the individual furnishing the vehicle). 2. A means to indicate the nature and due date of the various inspection and maintenance operations to be performed. 3. A record of inspection, repairs and maintenance indicating their date and nature. 4. A complete lubrication record. Record Retention. The records shall be retained where the vehicle is either housed or maintained for a period of 1 year and for 6 months after the motor vehicle leaves the motor carrier s control. Required records. 1. Daily driver vehicle inspection report(s) required by Section 396.11(a). The records must be maintained for at least 3 months from the date the report was prepared [396.11(c)(2)]. 2. The original or a copy of the periodic (annual) inspection report required in Section 396.17. 3. Evidence of the qualification of the inspector. The inspector must be qualified in accordance with the provisions of 396.19. 4. Evidence of the qualifications of the brake inspector in accordance with the provisions of 396.25. CPM0611 3
Inspections Required: 1. Daily driver vehicle inspection reports in writing at the completion of each day s work on each vehicle operated as described in 396.11(a). [Form # 10] 2. Periodic (annual) inspection as described in 396.17 by a qualified inspector (may be your own) as outlined in 396.19. [Form # 11] 3. Anhydrous Ammonia/Liquefied Petroleum (LP) Gas Tanks (DOT Cargo Tank Specification MC 331) as described in 49CFR180.407(c) must be inspected as follows by a DOT-registered inspector: 1 st test by: Interval period after 1 st test External visual 9/1/91 1-year Leakage test 9/1/91 1-year Internal visual 9/1/91 5-years Pressure retest (hydrostatic) 9/1/95 5-years 4. Bulk fuel tankers (Same as 3, with 1 st pressure test required by 9/1/95 if less than 5 vehicles in the fleet. 5. Conditions requiring test and inspection of cargo tanks without regard to any other test or inspection: a. Cargo tank shows evidence of bad dents, corroded or abraded areas, leakage, or any other condition that might render it unsafe for transportation service. b. Cargo tank has been in an accident and has been damaged to the extent that it may have been adversely affected. c. The cargo tank has been out of hazardous materials transportation service for a period of one year or more. d. The cargo tank has been modified from its original design specifications. 6. All vehicles with MC 300, MC 301, MC 302, MC 303, MC 304, MC 305, MC 306, MC 307, MC 310, MC 311, and MC 312 specification cargo tanks must pressure test beginning 8/31/95.[49CFR180.405(g)(v). 7. Cargo tanks with MC 306, MC 307, MC 312, and DOT 406, DOT 407, and DOT 412 specifications built after 12/31/90 must have a manhole designed according to the specifications outlined in 49CFR178.354-5. Manhole assembly requirements are: a. 15-inch diameter on tanks with greater than 400 gallons. b. Must be structurally capable of withstanding, without leakage or permanent deformation that would affect its structural integrity, a static internal fluid pressure of at least 36 psig or cargo tank test pressure, whichever is greater. CPM0611 4
Inspections required c. Must be equipped with a safety device that prevents the cover from opening fully when internal pressure is present. d. Must be secured with fastenings that will prevent opening of the covers as a result of vibration under normal transportation or shock impact due to a rollover. e. Must be permanently marked by stamping or other means with: (1) Manufacturer s name (2) Test pressure psig (3) A statement certifying that the manhole meets the requirements of 49CFR178.354-5. CPM0611 5
Cargo Tank Testing Compliance Dates Inspections and Retests under 49CFR180.407(c) Test or Inspection (Cargo tanks specifications Date by which test must Interval after first configuration and service) be completed test EXTERNAL VISUAL INSPECTION (Inspection marking - V) All cargo tanks 1 year INTERNAL VISUAL INSPECTION (Inspection marking - I) All cargo tanks transporting lading corrosive to the tank 1 year All other cargo tanks, except MC 338 September 1, 1995 5 years LEAKAGE TEST (Inspection marking - K) All cargo tanks, except MC 338 1 year PRESSURE TEST (Inspection marking - P) (Hydrostatic or pneumatic) All cargo tanks September 1, 1995 5 years THICKNESS TEST (Inspection marking - T) All unlined cargo tanks in corrosive service, except MC 338 September 1, 1992 2 years REPORTING AND RECORDKEEPING: (1) Owners of spec cargo tanks must retain the manufacturer s data report ( birth certificate ) or certificate and related papers certifying that the spec cargo tank was manufactured and tested in accordance with applicable specifications. These documents shall be retained throughout ownership plus 1 year thereafter. (2) If the owner does not have the manufacturer s certificate and cannot obtain one, the cargo tank may be certified by performing the appropriate test(s) and inspection(s) using a Registered inspector. Both the owner and the Registered inspector must certify that the cargo tank meets applicable specifications. (3) The owner of a spec cargo tank must retain a written report of the inspections and tests given including the type of test and inspections performed, the serial number of the tank, its DOT specification, test date, location of defects and methods of repair and disposition statement, the name, address, DOT registration number and signature of the Registered inspector, as well as the owner s signature. This documentation should be kept until the next test or inspection of the same type is completed. These requirements DO NOT APPLY if leasing the cargo tank for less than 30 days. ADDITIONAL RECORDKEEPING FOR SPEC MC 330 and MC 331 CARGO TANKS: (1) After completion of the pressure test and if the cargo tank has been or is to be placed in ANHYDROUS AMMONIA, LP GAS, OR any other service that may cause stress, corrosion, or cracking, the owner must make a written report. (2) The report must contain the carrier s name, address, and telephone number, complete ID plate data from the tank, a statement indicating whether or not the tank was stress relieved after manufacture, name and address of person performing the tests and the date of the test, a statement of the nature, severity, and location of any defects found, methods used to make repairs, who performed the repairs and whether or not the tank was stress relieved after repairs, a statement of disposition of the tank and a statement indicating that the tank is in anhydrous ammonia or LP Gas service and a statement indicating whether each shipment of ammonia was certified by the shipper as containing CPM0611 6
Cargo Tank Tests and Inspections 0.2 percent water by weight. (3) A copy of this report must be retained at the principal place of business for the duration of ownership and 1 year thereafter. This does not apply if the cargo tank is leased for less than 30 days. Marking Symbol V K I (See Note 2) P T Test or Inspection Test Interval Year Cargo Spec Tank # s MC300, MC301, MC302, MC303, MC304, MC305, MC306, MC310, MC311, DOT406 Spec Tank # s MC307, MC312, DOT407, DOT412 Spec Tank # s MC330, MC331 Date by Which First Test Must Be Completed External Visual Inspection 1 X X X 9/1/91 Leakage Test 1 X X X 9/1/91 Internal Visual Inspection 5 X X X 9/1/95 Pressure Test 5 X X Thickness Test 2 (See Notes 4 & 5) (See notes 4 & 5) (See Note 3) 9/1/95 (See notes 4 & 5) 9/1/92 NOTES 1. The X indicate that a test or inspection is required for that particular cargo tank listed in the top row. 2. Internal visual inspection is not required for tanks not equipped with a manhole or inspection opening. 3. Cargo tanks equipped with manholes and constructed of quenched and tempered steel (QT) used for the transportation of anhydrous ammonia, LP Gas or any other hazardous material which may cause stress, corrosion, or cracking must be internally inspected by the wet fluorescent magnetic particle method. This inspection is performed immediately prior to, and in conjunction with, the pressure test. The only marking requirement is the P symbol required for the pressure test. 4. For all unlined cargo tanks transporting lading that is corrosive to the tank. 5. Thickness testing, along with other tests and inspections, is required if the cargo tank shows evidence of dents, corrosion, abrasion, leakage, has been damaged in an accident, or shows any other condition that may make it unsafe for transportation. If the cargo tank has been out of hazardous materials transportation for 1 year or more, it must be fully inspected and tested in order to bring the tank back into hazardous materials service. CPM0611 7
Cargo Tanks Compliance Dates - Inspections and Retests 49CFR180.407(c) Test or inspection (cargo tank specification, configuration and service) External visual inspection: (Inspection marking = V) 1. All cargo tanks designed to be loaded by vacuum with full opening rear heads. 2. All other cargo tanks Internal visual inspection: (Inspection marking = I) 1. All insulated cargo tanks except MC330, MC331, & MC338 2. All cargo tanks transporting lading that is corrosive to tank 3. All other cargo tanks except MC338 Date by which first test must be completed. (Note 1) Interval period after first test 6 months 1 year 1 year 1 year 5 years Lining inspection (Inspection marking = L) 1. All lined cargo tanks transporting lading that is corrosive to the tank 1 year Leakage test (Inspection marking = K) 1. All cargo tanks except MC338 1 year Pressure test (Hydrostatic or pneumatic; Inspection marking = P) 1. All cargo tanks which are insulated with no manhole or insulated and lined, except MC338 2. All cargo tanks designed to be 1 year loaded by vacuum with full opening rear heads. 3. MC330 & 331 cargo tanks in September 1, 1992 2 years chlorine service 4. All other cargo tanks September 1, 1992 September 1, 1995 2 years 5 years Thickness test: (Inspection marking = T) 1. All unlined cargo tanks in corrosive service, except MC338 September 1, 1992 2 years CPM0611 8
Compliance Dates - Inspections and Retests Note 1: If a cargo tank is subject to an applicable inspection or test under the regulations in effect on 12/30/90 and the due date (as specified by a requirement in effect on 12/30/90) for completing the inspection or test occurs before the compliance date in this table, the earlier date applies. Note 2: Pressure testing is not required for MC 330 & 331 cargo tanks is dedicated sodium metal service. Note 3: Pressure testing is not required for non-insulated lined cargo tanks, with a design pressure or MAWP 15 psig or less, which receives a yearly external visual and lining inspection. CPM0611 9
Maintenance file for each vehicle controlled for 30 days or more Item 1. Identification of vehicle to include: a. Company number if so marked b. Make c. Serial number (VIN) d. Year e. Tire size f. Leased vehicles identify the owner/provider 49 CFR Reference 396.3(b) Expires 1 year + 6 months after vehicle leaves company 2. Schedule of maintenance 396.3(b)(3) (written maintenance plan) 3. Record of Inspection, Repairs 396.3(b)(3) and Maintenance (indicating date and nature of repair/inspection) 4. Copy of all roadside inspections 396.3(b) (3) 12 months from date of inspection 5. Daily Vehicle Inspection Reports 396.9(d)(3) 3 months (DVIR) (certificate of repairs and certification of driver s review) 6. Documentation of periodic 396.11(c)(2) continuously inspection (report or other document such as a sicker or decal) 7. Evidence of individual s qualification to conduct annual 396.23(a) 396.17 (c) inspections 8. Periodic inspection report 396.19(b) 14 months (annual inspection) (original or copy) 9. Evidence of a brake inspector s qualifications 396.21(b)(10 CPM0611 10
ANNUAL VEHICLE INSPECTION---INSPECTOR CERTIFICATION This form can be ordered from JJ Keller Associates, Inc. or other vendor CPM0611 11