MODULE 7

1. MODULE 7 Vehicle Inspection

2. Module 7 – Vehicle Inspection Introduction If you drive any propane delivery vehicle, you are considered to be a professional driver. As a professional driver, you must keep your vehicle in good condition to maintain its safety. Inspections are the best way to maintain vehicle safety and find problems before they cause an accident or breakdown. This module discusses both general guidelines and specific information for inspecting bobtails, transports, cylinder trucks, crane trucks, and tank trailers. This module can serve as a guide for regular vehicle inspections. However, you should always follow your company’s inspection policies and procedures as well. After completing this module, you will be able to: • Explain why inspections are important. • Identify the three types of vehicle inspections. • Discuss the six-step inspection procedure. • List the criteria for placing a vehicle out of service.

3. LESSON 1 The Importance of Vehicle Inspections

4. The Importance of Vehicle Inspections Introduction DOT Federal Motor Carrier Safety Regulations (FMCSR) require the periodic inspection of commercial vehicles. Inspections are simple and provide many benefits, including reducing accidents and breakdowns. Inspections are essential to keep both you and others safe while on the road. After completing this lesson, you will be able to: • Identify when to perform vehicle inspections. • Identify the different types of vehicle inspections required.

5. When to Perform Inspections Propane industry drivers are required to make three types of vehicle inspections: • Pre-trip. • On the road. • Post-trip. A pre-trip inspection is your best opportunity to assess the mechanical integrity, safety, and road-worthiness of the Commercial Motor Vehicle (CMV) you are about to operate. Pre-trip inspections help ensure that the condition of the vehicle has not changed since it was last operated. You must do a pre-trip inspection before taking any CMV out on the road, even if it was used by another driver during the same day.

6. When to Perform Inspections, cont. Follow the same inspection procedure every time, and always check the post-trip Driver Vehicle Inspection Report (DVIR) from the previous shift to see if any problems were noted with the vehicle. While on the road, watch your gauges for signs of possible trouble and be aware of changes in the vehicle’s operation or performance. You must inspect your load when you make a stop, within 50 miles after starting out, and every 150 miles following or every three hours, whichever comes first. You must do a post-trip inspection at the end of your shift. You will learn more about the post-trip inspection later in this course.

7. Additional Types of Inspections You are responsible for meeting the requirements for the three basic types of vehicle inspections just mentioned. However, you should also be aware of additional inspections required by DOT, including: • Inspections following a breakdown where the vehicle was towed away. • Periodic inspections. • Qualification of brake inspections. Brake inspections can be performed only by qualified inspectors. Your company is responsible for making sure these inspections meet all DOT requirements. Drivers must regularly check that their vehicle’s brakes are working properly, but they are not allowed to adjust or repair them. If you believe there is any issue with your brakes, notify your supervisor immediately.

8. CHECK FOR UNDERSTANDING

9. LESSON 2 Six-step Inspection Method

10. Six-Step Inspection Method Introduction It is useful to have a set procedure for performing inspections. Performing the pre- and post-trip inspections consistentlyimproves the likelihood of finding problems that need to befixed. This lesson describes a procedure that can help you perform pre- and post-trip inspections consistently. The procedure covers: • Vehicle Overview. • Engine Compartment. • Walk-Around Inspection. • Inside the Cab. • Lights. • Brake System. Though your company procedures may vary, the inspection procedure explained in this section can serve as a useful guide and reference. After completing this lesson, you will be able to identify and explain the six steps in performing pre- and post-trip vehicle inspections.

11. Preparing for Inspection Before beginning an inspection, make sure you have all the tools you may need and that the vehicle is ready. To prepare your vehicle: Park it on a level surface, away from people, other vehicles, low-hanging wires or tree limbs, or anything that may become a hazard. • Remove the keys from the ignition. • Set the parking brake. • Chock the wheels. • Find a clean rag for wiping lights and reflectors. • Have the tire pressure gauge available.

12. Step 1: Vehicle Overview As you approach the vehicle for a pre-trip inspection, take some time to observe its general condition. Things to look for include: • Obvious damage to the body of the vehicle, or anything that could cause problems when you are on the road. • Signs of fresh oil, coolant, grease, or fuel leaks underneath the vehicle. • The condition, visibility, and placement of placards. Placards are required when transporting a hazardous material. If any placards are faded or damaged, replace them. Make sure placards are affixed and visible on all four sides of your vehicle. Remove the placards from your truck when not transporting a placard-requiring load of hazardous material.

13. Step 1: Vehicle Overview, cont. Additional information on placards and their placement can be found in Module 3, “DOT General Awareness Hazmat Training,” of this course. Before continuing the inspection, check the previous DVIR for any problems noted. If a problem affecting safety was listed on the report, it must be repaired before you operate the vehicle. Look for a certification or mechanic’s signature showing the required repairs have been made. As the current driver, you must also confirm the stated repairs have been completed and sign the DVIR so the vehicle can be placed back in service.

14. Step 2: Engine Compartment Before inspecting the engine compartment, make sure the parking brake is engaged and chock blocks are set. When this is done, open the hood and check the: • Engine oil level. • Coolant level in radiator and condition of hoses. • Power-steering fluid level and condition of hoses and pumps. • Windshield-wiper fluid level. • Battery fluid level, connections, and tie-downs. • Automatic transmission fluid level. • Alternator, water pump, air compressor belts, air conditioner belts.

15. Step 2: Engine Compartment, cont. Also look for fuel, coolant, oil, or other fluid leaks, and cracked or worn electrical wiring insulation. Lower and secure the hood, cab, or engine compartment door. Check compressed-air tanks for obvious leaks, and purge them of water by opening and closing the drain cocks on the bottom of each tank. Also, double-check all hood latches to ensure they are present and working as designed.

16. Step 3: Walk-Around Inspection You are now ready to perform the walk-around inspection, which involves inspecting the outside of the entire vehicle. Start your inspection with the sides of the vehicle: • Windows, mirrors, and lights should be clean and free of chips or other damage. • Wheels, rims, and lug nuts should not be missingor bent, or have broken spacers, studs, or clamps. • Make sure the tires are inflated properly, have no excessivetread wear, and are the same size (not mixed radial and bias types). • Be sure shock absorbers, springs, spring hangers, shackles, and u-bolts are in good condition and not loose. Air suspension parts should not show signs of leaks. • Brake drum/rotors and hoses should be in good condition with no signs of leaks. • The fuel tank and must be securely mounted and capped. Check that it is not damaged or leaking and has adequate fuel. Check that the fuel crossover line is secure.

17. Step 3: Walk-Around Inspection, cont. • Check the engine and transmission for signs of leaks. • Exhaust system should be secure, leak-free, and not touching wires, fuel lines, or air lines. If you have a heat shield, make sure it is secure and in good condition. • Make sure front axle, frame, and cross members are not bent or cracked. • Spare tire and carrier rack should be free of damage; the spare tire is securely mounted, the right size and properly inflated. • Windshield and wiper blades should be in good condition with proper tension on the wiper arms. • License plates must be present, clean, and secure. • Mud flaps must also be present, secure, and not damaged.

18. Step 4: Inside the Cab While inside the cab of your vehicle, place the gearshift in neutral or park. Start the engine and listen for any unusual noises. If everything sounds normal, check the following: Gauges Oil pressure comes to normal within seconds after starting the engine; the ammeter and/or voltmeter is in normal range; engine temperature gradually rises to normal; air pressure builds to 100–125 psi within 3-5 minutes; oil, coolant, charging circuit-warning lights go out right away; and air flow from defroster/heater can be felt.

19. Step 4: Inside the Cab, cont. Controls Check all of the following for looseness, sticking, damage, or improper setting: steering wheel/steering column; clutch; accelerator; foot brake; parking brake; front brake limiting valve; tractor protection valve; retarder controls; transmission controls; and inter-axle differential lock. Steering wheel play of more than 10° can make it hard to steer. Steering wheel play of 30° or more is illegal. Safety Items Check the condition of the horn and windshield wipers and washers. Check mirrors for proper adjustment. Inspect mirrors and windshield for cracks, dirt, illegal stickers, discoloration, and other visual obstructions.

20. Step 4: Inside the Cab, cont. While in the cab, also check to make sure that you have the following items: Emergency Equipment Check all required emergency equipment including spare electrical fuses, three red reflective triangles, and a properly charged and rated fire extinguisher. Optional emergency equipment include: tire chains; tire changing equipment, a list of emergency phone numbers, an accident report kit, and a first aid kit.

21. Step 4: Inside the Cab, cont. Paperwork Make sure you are carrying proper paperwork including: emergency response information; shipping papers; hazmat certificate of registration; vehicle registration; insurance verification; and emergency operating procedures. Place the shipping papers and required accompanying documents somewhere clearly visible to anyone entering the cab, and within arm’s reach of the driver with the seat belt fastened.

22. Step 5: Lights Make sure all of your lights are clean, free of cracks, not missing screws, free of condensation, and in good working condition. If possible, ask someone nearby to help you with your checks. Explain the order in which you will be turning on lights, and let you know if the lights are working properly. Be sure to check: • Low-beam headlights. • High-beam headlights. • Four-way flashers. • Parking, clearance, side-marker, and license plate lights. • Brake lights. • Turn-signal lights.

23. Step 6: Brake System To ensure your brakes are functioning correctly, perform this final step of the procedure according to the type of vehicle you drive: Parking Brake Start the vehicle, engage the parking brake, and gently pull against the brake in a low gear to test that it will hold. Service Brakes Wait for normal air pressure, release the parking brake. Move the vehicle forward at about 5 mph, and apply the brakes firmly. Note any pulls to one side, unusual feels, or delayed stopping action.

24. Step 6: Brake System, cont. Air Service Brakes Build air pressure up to 100–120, cut the engine off, and release all brakes. Press the foot brake firmly, and hold down for one minute. Air pressure should not drop over more than 3 PSI for straight truck vehicles or for truck/ trailer (pentle hook) vehicles or combination vehicles. Turn the ignition key to the “ON” position and continue pumping the foot brake with the air pressure down. Watch for the “Low Air” buzzer and/or a warning light at around 60. At 40, the release valves should pop out for the truck and trailer. As you complete all of these inspection steps, make note of any potential problems. If anything unsafe is found, it must be repaired before the vehicle is driven.

25. LEARNING ACTIVITY Discovery: Vehicle Inspection

26. LESSON 3 Vehicle-Specific Inspection Procedures

27. Vehicle-Specific Inspection Procedures Introduction Many different types of vehicles are used in the propane industry, such as transports, tank trailers, bobtails, crane trucks, and cylinder trucks. These vehicles require inspection steps beyond the six-step inspection described in the previous lesson. As the driver of these vehicles, you are also responsible for following your company’s specific inspection policies as well as the vehicle’s operating manual inspection recommendations. After completing this lesson, you will be able to identify additional inspection steps when using: • Transport Vehicles. • Tank Trailers. • Crane Trucks. • Bobtails. • Cylinder Trucks.

28. Additional Steps for Transports – Step 6: Final Brake System Check Transports pull trailers equipped with their own brakes. Use this step to test the following parts of the braking system for your vehicle and trailer: Parking Brake Start the vehicle. Engage the vehicle’s parking brake (the yellow, four-sided button), and gently pull against the brake in a low gear to test that the parking brake will hold. Trailer Emergency Brakes Charge the trailer air-brake system. Check that the trailer rolls freely. Stop and pull out the tractor protection valve control, or place it in the emergency position (the red, eight-sided button). Pull on the trailer to check that the emergency brake is on. Service Brakes Wait for normal air pressure, release the parking brake, move the vehicle forward at about 5 mph, and apply the brakes firmly. Note any pulling to one side, unusual feel, or delayed stopping action.

29. Additional Steps for Transports – Step 6: Final Brake System Check, cont. Trailer Service Brakes Check for normal air pressure, release the parking brakes, move the vehicle forward slowly, and apply the trailer brakes with the hand control (trolley valve), if so equipped. You should feel the brakes come on. This tells you the trailer brakes are connected and working. (The trailer brakes should be tested with the hand valve but controlled with the foot pedal, which applies air to the service brakes.) You should also check: • The Air Leakage Rate. • The Low-Pressure Warning Signal. • The Tractor Protection Valve. • Air-pressure Buildup. • The Air Compressor Governor. • The Cut-in and Cut-out Pressure.

30. Additional Steps for Transports – Step 8:CouplingSystem Areas Check to make sure the fifth wheel is mounted securely to the frame rails and is properly lubricated. Also verify the fifth wheel is not so far forward that the tractor frame will hit any landing gear or that the trailer will damage the cab during turns. The king-pin locking mechanism should also be checked for proper contact, possible wear or missing parts, and security of the release lever. Make sure all air lines and electric cables running to the trailer are free from damage and secured properly. Air lines should be free of leaks with enough slack for turns.

31. Additional Steps for Transports – Step 8: Tank andHose Areas Other specific inspection procedures depend on the tanker type you operate. However, you always need to perform the following pre-trip inspections to ensure that: • Hoses are stowed and secured. • Valves are closed and secure. • Tanks are not leaking. • Hazardous materials placards are displayed. Transports must also be equipped with a passive shutoff system. This system is designed to shut down the propane discharge within 20 seconds of complete hose separation. Typically, this shutdown capability is provided by a specially designed hose with automatic shutoff mechanisms on each end of the hose that actuate during a hose pull-away.

32. Additional Steps for Tank Setting Trailers Before using the trailer hitch system on your tank trailer, check to make sure: • The electrical connector is firmly plugged in and secured. • All trailer hitch/pentle hook components are secure. • Safety chains are properly attached and secured to the trailer and towing vehicle. • Cargo straps and chains are in good working condition. If the trailer is equipped with brakes, test the brakes before driving to ensure they work properly. If they are not performing properly, the trailer must be taken out of service until it has been repaired properly.

33. Additional Steps for Crane Trucks Boom trucks are becoming more popular in the propane industry. These specially-fitted trucks are designed primarily to lift, transport, and place customer tanks and cylinders. Crane trucks are particularly useful for setting underground tanks. In addition to checking the cab and chassis unit for safety-related problems, check the following crane-specific issues before you leave your facility: • Exposed parts, gears, and chains are guarded properly. • Wire rope, related hooks, and securing components are in good condition. • The boom angle indicator is operable. • The main hoist and drum assembly are in good condition. • Electrical wiring and related connections show no wear or fraying.

34. Additional Steps for Crane Trucks, cont. • Condition of hydraulic hoses, fittings, and related tubing. • Condition of hydraulic hoses, fittings, and related tubing. • Condition of truck outriggers. • Condition of turn-table mechanism and crane body. • Condition of all safety stops and safety mechanisms. • Always consult your company policy for more information relating to crane safety.

35. Additional Steps for Bobtails DOT requires bobtails be equipped with remote-control shutoff devices operated by radio frequency (RF). This device gives operators the ability to shut off the engine and unloading operations by closing the bobtail’s liquid self-closing internal valve from a minimum of 150 feet away. This technology helps prevent a major release of propane and eliminates a source of ignition in an accident. Bobtails with a capacity greater than 3,500 gallons must also be equipped with a query system or passive shutdown capability. When the query system is used, the qualified person attending the unloading operation must carry a transmitter/receiver.

36. Additional Steps for Bobtails, cont. The query system closes the internal, self-closing stop valve and shuts off all motor and auxiliary power equipment unless the transmitter/receiver is activated at least once every five minutes. This safety feature prevents an unintentional release if the driver is distracted or incapacitated. The RF device and query system must be tested at a minimum of 150 feet away from the truck. This test must take place prior to putting the vehicle on the road, and no more than 18 hours before the first delivery of the day.

37. Additional Steps for Cylinder Trucks Before loading a cylinder delivery vehicle, inspect the bed to ensure that: • The floor of the vehicle bed is level and securement fixtures such as racks, cages, tie-down bars, and latches are in good condition. • The cylinder-securing devices are in good condition. • The vehicle bed will allow cylinders to be restrained securely in an upright or horizontal position, loaded onto racks, or packed into boxes or crates, respectively.

38. LESSON 4 Hose Inspections

39. Hose Inspections Introduction DOT requires you to perform visual inspections of the hose assembly and the deployed portion of the hose after each delivery. Check for any defects while you are reeling in the hose. Reject any hose showing: • Damage to the hose cover that exposes the wire braid reinforcement. • Kinking or flattening that has deformed the reinforcement. • Soft spots when not under pressure. • Bulging under pressure. • Loose outer covering. • Damaged, slipping, or excessively worn hose couplings. • Loose or missing bolts or fastenings on bolted hose coupling assemblies.

40. Hose Inspections Introduction, cont. Immediately replace a hose with any of the above defects. Never use a damaged or defective delivery hose assembly. NOTE: While you may be able to identify problems visually with a hose, only a qualified individual with a Certified Tester (CT) number is allowed to test and repair hoses. Never make field repairs on a hose yourself.

41. Monthly Hose Assembly and Piping System At least once a month, you must: • Inspect the delivery hose assembly and piping system. • Test the emergency discharge control devices. • Test the internal, self-closing stop valve in the liquid discharge opening for leakage (meter creep test). You must document monthly inspections and tests. This documentation must include: • Inspection date. • Name of the person performing the inspection.

42. Monthly Hose Assembly and Piping System, cont. • Hose assembly identification number. • Company name. • Date the hose was assembled and tested. • Whether the delivery hose assembly and piping system passed or failed. A copy of this record must be maintained until the next monthly inspection test is successfully completed.

43. Documented Leakage Tests Internal, self-closing stop (belly) valves must be checked within 18 hours of the first delivery to ensure their proper operation. Documenting this daily check is not required by DOT; however, your company may require it. The following leakage tests require documentation by DOT: Meter Creep Test: For cargo tanks in metered service, the internal, self-closing stop valves must be tested monthly for leak-tight integrity by performing a “meter creep” test that must be documented and kept on file. More information on how to perform a “meter creep” test can be found later in this lesson. Leakage Test for Nonmetered Vehicles: For cargo tanks in nonmetered service, you can perform the monthly check for leakage by closing the internal, self-closing stop valve so that all of the material in the downstream piping is evacuated. When the piping returns to atmospheric temperature and pressure, monitor the outlet for 30 seconds. Any detectable leakage is considered unacceptable.

44. Documented Leakage Tests, cont. Annual Hose Inspections: In addition to the monthly inspection described, previously, hoses must also be tested annually for leakage as part of the cargo tank annual visual (V) inspection and leak test (K) protocol. New or Repaired Hose Assemblies: Cargo tank operators must ensure that new or repaired delivery hose assemblies are tested at a minimum of 120 percent of the hose’s maximum working pressure. The hose assembly must be examined visually during this test. If there are no leakage or defects detected, the hose assembly must be marked permanently with the month and year of this test. Because truck models and their systems vary, it is important to understand the specific workings of your truck when performing these tests. Review with your supervisor how to conduct leakage tests on any cargo tank vehicle you will be operating.

45. CHECK FOR UNDERSTANDING

46. LESSON 5 Post-Trip Inspections

47. Post-Trip Inspections Introduction Post-trip inspections are vital to ensure that your vehicle is maintained properly. Because the condition of your vehicle may change during the day, it is important to inspect it immediately after you complete your trip. This way, if you find a problem, there is a better chance of obtaining timely repairs and minimizing schedule disruptions. DOT regulations require a Driver Vehicle Inspection Report (DVIR) to be filled out for each vehicle at the end of the workday. On this report, you are required to list any defects that would affect the safe operation of your vehicle or result in a breakdown. The DVIR must include the condition of: • Service brakes, including trailer brake connections. • Steering mechanism. • Windshield wipers.

48. Post-Trip Inspections Introduction, cont. • Horn. • Coupling devices. • Parking (hand) brake. • Lighting devices and reflectors. • Tires, wheels, and rims. • Rear-vision mirrors. • Emergency equipment, including fire extinguisher, reflective triangles, and spare electrical fuses.

49. Understanding the DVIR The DVIR helps drivers conduct pre- and post-trip inspections by listing all of the common parts and systems that must be examined. This report must be completed during the post-trip inspection and reviewed during the pre-trip inspection to ensure any noted defects have been repaired. The top portion of the DVIR contains vehicle identification information. Be sure to record the vehicle number and the date you are performing the inspection. The next section of the DVIR provides a list of what you must inspect. If any item is not working correctly, place a checkmark in the box provided. Write a detailed explanation of the problem in the “Remarks” section.

50. Understanding the DVIR, cont. If no repairs are needed, place a checkmark in the appropriate box, sign the DVIR, and leave a copy in the vehicle for the next shift. If repairs are needed, record them and sign the DVIR. Take a copy to the office or other designated place to notify your supervisor or mechanic of the needed repairs. The mechanic or an authorized person will sign the DVIR to certify the repair work was done, and leave a copy in the vehicle for the next trip. Always consult your company policy for specific post-trip inspection procedures.