Vehicle Repair and Maintenance Checklist

Create the PM work order in Fleetio (or RTA / Whip Around) against the unit number. Pull the maintenance history and any open driver DVIR defects from the prior trip — those defects must be addressed before this unit returns to service per Part 396.11.

Pull the last 7 days of DVIRs from the ELD platform (Motive, Samsara, KeepTruckin). Any defect marked as affecting safe operation must be repaired and signed off by a mechanic before release — Part 396.11(c).

Dipstick reading on a level surface, engine off for 10 minutes. Note color and viscosity — milky indicates coolant intrusion; gritty indicates injector cup failure on a DD15 or ISX. Flag for sample if either is present.

Look at the transmission pan, output seal, and inter-axle drive shaft on tandems. A pinion seal weep on a Meritor or Dana rear is common and should be quoted now rather than at the next service.

Top off coolant at the surge tank and DEF at the blue cap. Pull diagnostic codes for DPF soot load, EGR delta-pressure, and SCR efficiency — clogged DPFs and crystallized DEF dosers are the most common roadside breakdowns on post-2010 engines.

Check serpentine belt for glazing and cracks every 3 inches; replace if either is present. Pull the air filter and check the restriction gauge — replace at 25 inH2O. Inspect charge-air-cooler hoses at the clamps for oil residue indicating a turbo boost leak.

Lining thickness below 1/4" on the shoe or 1/8" on a steer axle puts the unit OOS per CVSA. Measure drum diameter against the maximum stamped on the drum — discard at the limit, not when it looks worn.

Chock the wheels, pump air to 100 psi, release, and apply with engine off. Mark the pushrod and measure stroke at 90-100 psi. A Type-30 long-stroke is OOS at 2". Two or more brakes 20%+ out of adjustment = OOS. Automatic slacks must not be manually adjusted to mask a failed component.

Build to governor cut-out, shut down, and apply foot brake. Leak rate must not exceed 3 psi/min single, 4 psi/min combination with brakes applied. Verify low-air warning at ~60 psi and spring brake pop-out at 20-45 psi.

Steers must be at or above 4/32"; drives and trailer above 2/32". Check pressure cold against the door sticker (typically 105-110 psi steers, 100 psi drives). Note any sidewall cuts, bulges, or exposed cord — all are immediate OOS.

Check hub oil level at the sight glass; cloudy oil indicates water intrusion. Look for grease at the back of the wheel (failed inner seal) and rust trails at lug nuts (loose wheel). Re-torque to manufacturer spec on any wheel that has been off in the last 100 miles.

Free play in a 20" steering wheel above 2" is OOS. Have a helper rock the wheel while you watch the drag link, tie rod ends, and pitman arm for any movement at the joints — any visible movement at the stud is a replacement.

One cracked or broken leaf is repairable; a broken main leaf or 25% of the leaves broken is OOS. On air-ride, look for chafing on the bag and leaks at the height-control valve linkage.

Gauge the jaw-to-kingpin gap with a Holland or Fontaine gauge — over 1/2" horizontal is OOS. Check secondary lock engagement and mounting bolt torque. Grease the top plate; dry plates cause hard couplings that bend kingpins.

Hit all zerks per the OEM schedule — spring pins, slack adjusters, S-cam bushings, drive line U-joints and slip yoke, fifth wheel. Use chassis grease, not wheel-bearing grease.

Headlights (high and low), turn signals, four-way flashers, brake lights, marker lamps, ICC bumper lights, and license plate lamp — all required per Part 393.11. One inoperable lamp on a combination vehicle drops a CSA point on a roadside; multiple inops are OOS at night.

Load-test each battery; replace any reading below 75% CCA. Clean terminals and check ground straps to frame. Alternator should hold 13.8-14.2V at fast idle with lights on.

Confirm the ELD (Motive, Samsara, Geotab) powers up, syncs to ECM, and shows the correct driver if assigned. Check all dash warning lamps illuminate at key-on and extinguish at run. A malfunctioning ELD must be repaired within 8 days per Part 395.34.

Inoperative defroster or wipers is OOS in inclement weather. Replace blades that streak. Verify mirror heat on units with heated mirrors.

Same brake-stroke and lining standards as tractor. Verify ABS lamp on trailer extinguishes after a couple of seconds — Part 393.55 requires functional ABS on trailers built after March 1998.

Crank landing gear through both speeds; replace gearbox if it grinds or skips. Check door seals for daylight and floor for soft spots that will fail at a pallet jack.

On Carrier or Thermo King units, run a pre-trip self-test and a pull-down from ambient to 0°F. Check belts, defrost cycle, return-air sensor, and fuel level. Download the temperature recorder data and confirm the last download is within the customer's required interval.

Count and inspect chains, binders, straps, edge protectors, and tarps against the Part 393 Subpart I working-load-limit requirements. Pull any chain with bent links or strap with cuts deeper than 25% of the width.

Part 393.95 requires: one 5-BC fire extinguisher (or two 4-BC for hazmat), three bidirectional reflective triangles, and spare fuses for any non-circuit-breaker-protected circuit. Confirm extinguisher gauge is in the green and the inspection tag is current.

Part 396.17 annual inspection decal must be within 12 months on every CMV unit and trailer. Also verify IRP cab card, current registration, IFTA decals on both sides of the cab, and HVUT 2290 Schedule 1 on file for plate renewal.

The shop manager reviews the technician's findings and decides disposition. Any CVSA OOS condition must be corrected before this unit is dispatched.

Hang the OOS tag in the cab, lock the keys in the shop board, and notify dispatch so the unit is not assigned a load. Create the follow-up work order with the failed item, parts ETA, and target return-to-service date.