Commercial Vehicle Pre‑Trip Inspection Checklist

Step-by-step procedures to ensure DOT compliance and safe operation of commercial vehicles

Pre-Inspection Preparation

  • Park vehicle on level ground and apply parking brake.
  • Turn off engine and remove keys from ignition.
  • Gather inspection equipment: flashlight, tire gauge, gloves.
  • Obtain previous Driver Vehicle Inspection Report (DVIR).
  • Review any previous defects and verify repairs completed.
  • Note current mileage and hours (if equipped with hour meter).

Engine Compartment Inspection

  • Open hood and secure with prop rod or latch.
  • Check engine oil level with dipstick - should be between MIN and MAX.
  • Inspect coolant level in overflow reservoir (when engine is cold).
  • Verify power steering fluid level at proper mark.
  • Check windshield washer fluid and fill if needed.
  • Inspect all belts for proper tension, cracks, or fraying.
  • Check all hoses for leaks, cracks, or loose connections.
  • Look under vehicle for any fluid leaks or puddles.

In-Cab Safety Check

  • Verify fire extinguisher is present, charged, and properly mounted.
  • Check for three reflective warning triangles in proper case.
  • Ensure spare electrical fuses are available (if applicable).
  • Test seat belt for proper operation and secure latching.
  • Adjust all mirrors for optimal visibility.
  • Start engine and test horn for proper operation.
  • Check all dashboard gauges and warning lights.
  • Test windshield wipers and washer spray.
  • Verify heater/defroster and air conditioning operation.

Brake System Testing

  • Press brake pedal firmly - should not go to floor.
  • Check brake fluid level in master cylinder reservoir.
  • Test parking brake - should hold vehicle securely on incline.
  • For air brakes: Check air pressure gauge readings.
  • Build air pressure to governor cutoff (typically 120-140 psi).
  • Test low air pressure warning device (should activate before 60 psi).
  • Perform air leak test - loss should not exceed DOT limits.
  • Check brake adjustment and push rod travel.

Lights and Electrical System

  • Turn on headlights and check high/low beam operation.
  • Test left and right turn signals - front and rear.
  • Verify all clearance and marker lights are working.
  • Check brake lights with assistant or reflection.
  • Test 4-way hazard flashers for proper operation.
  • Inspect all light lenses for cracks or damage.
  • Verify backup lights illuminate when in reverse.
  • Check license plate light for proper illumination.

Tires, Wheels, and Suspension

  • Check tire pressure on all wheels including spare.
  • Inspect tread depth - minimum 4/32" on steer, 2/32" on others.
  • Look for cuts, bulges, or irregular wear patterns.
  • Verify all lug nuts are present and properly tightened.
  • Check for cracks or damage to wheel rims.
  • Inspect hub oil seals for leaks (if visible).
  • Check suspension components for damage or excessive wear.
  • Verify shock absorbers are secure and not leaking.

External Walk-Around

  • Check body panels for damage or loose components.
  • Verify all doors latch securely and locks function.
  • Inspect cargo area for cleanliness and security.
  • Check load securing devices (straps, chains, bars).
  • Verify mud flaps are present and secure.
  • For trailers: Check fifth wheel or pintle hook connection.
  • Inspect air and electrical connections to trailer.
  • Verify trailer brake operation and lights.
  • Check that license plates are clean and visible.

Final Steps and Documentation

  • Start engine and let idle while checking gauges.
  • Listen for unusual noises or vibrations.
  • Test service brakes at slow speed in safe area.
  • Record all defects found during inspection.
  • Complete Driver Vehicle Inspection Report (DVIR).
  • Report any defects to maintenance immediately.
  • Do not operate vehicle if defects affect safety.
  • Sign and date inspection report for records.
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