Complete CDL Pre-Trip Inspection Procedure

The most comprehensive pre-trip inspection guide for CDL drivers. This complete checklist ensures full DOT compliance and maximum safety.

8
Major Sections
100+
Inspection Points
30-45
Minutes Required
Federal CDL Requirements

This comprehensive inspection exceeds all FMCSA requirements for pre-trip inspections. CDL holders must be able to identify and explain each component during testing and perform this inspection before every trip.

1 Overview Inspection - General Vehicle Condition

Begin with a complete walk-around to get an overall impression of the vehicle's condition.

  • Walk completely around the vehicle looking for obvious damage or leaning.
  • Check for any body damage that could affect safety or operation.
  • Look under the vehicle for fresh fluid leaks - oil leaves dark spots, coolant is green/orange, fuel has a rainbow sheen.
  • Verify current registration is displayed properly.
  • Check for current inspection sticker if required by your state.
  • Ensure USDOT number and company name are displayed as required.
  • Verify IFTA stickers are current if operating interstate.
  • Check that license plates are clean, visible, and properly secured.

2 Engine Compartment - Complete Inspection

Critical: Always check fluids with engine off and on level ground for accurate readings.

Fluid Levels Check

  • Engine Oil: Remove dipstick, wipe clean, reinsert fully, then check level between MIN and MAX marks.
  • Oil Condition: Check color - should be amber to light brown, not black. Check for metal particles.
  • Coolant (Radiator): Only check when engine is cool. Level should be visible at neck.
  • Coolant (Reservoir): Check level between MIN and MAX marks on translucent tank.
  • Power Steering Fluid: Check with engine off, level should be between marks.
  • Windshield Washer: Fill reservoir completely - you'll need it for visibility.
  • Battery: If not maintenance-free, check electrolyte level covers plates.
  • Automatic Transmission: If equipped, check with engine running, transmission warm.
  • DEF (Diesel Exhaust Fluid): Check level if equipped with SCR system.

Belts, Hoses, and Wiring

  • Belt Inspection: Check each belt for cracks, fraying, or glazing (shiny appearance).
  • Belt Tension: Press belt midway between pulleys - should deflect 1/2 to 3/4 inch.
  • Hoses: Squeeze hoses to check for soft spots, look for cracks, bulges, or leaks.
  • Clamps: Ensure all hose clamps are tight and properly positioned.
  • Wiring: Look for exposed wires, melted insulation, or loose connections.
  • Battery Cables: Check for corrosion (white/green powder) and tight connections.
  • Air Compressor: If belt-driven, check mounting bolts and belt condition.

3 Inside Cab Inspection

Gauges and Indicators

  • Turn key to ON position (don't start) - all warning lights should illuminate for bulb check.
  • Oil Pressure: Should show pressure within 15 seconds of starting.
  • Temperature: Should read normal operating range after warm-up.
  • Voltmeter/Ammeter: Should show charging (13.5-14.5 volts).
  • Air Pressure: Both primary and secondary should build to 100 psi within 45 seconds.
  • Fuel Gauge: Verify adequate fuel for trip plus reserve.
  • DEF Gauge: If equipped, ensure adequate level.
  • Warning Lights: All should go out after engine starts except parking brake.

Controls and Safety Equipment

  • Steering Wheel: Check for excessive play - maximum 10 degrees (2" at rim on 20" wheel).
  • Clutch: If manual, check for proper free play (1-2 inches).
  • Brake Pedal: Should be firm, not spongy, with adequate reserve.
  • Parking Brake: Test that it holds vehicle securely.
  • Horn: Test both electric and air horn if equipped.
  • Windshield Wipers: Check all speeds and washer operation.
  • Mirrors: Adjust all mirrors for maximum visibility, check for cracks.
  • Seat Belt: Check webbing for cuts, proper latching, and retraction.
  • Fire Extinguisher: Check gauge in green, proper rating (BC or ABC), and mounting.
  • Triangles: Three reflective triangles present and in good condition.
  • Spare Fuses: If applicable, ensure spares for each rating used.
  • Emergency Kit: First aid supplies, flashlight, and basic tools.

4 Steering System

The steering system is critical for vehicle control. Check thoroughly for any defects.

  • Steering Wheel Play: Turn wheel back and forth - lash should not exceed 10 degrees.
  • Steering Column: Should be securely mounted with no loose U-joints.
  • Steering Gear Box: Check mounting bolts and look for power steering leaks.
  • Pitman Arm: Check for looseness where it connects to steering gear.
  • Drag Link: No looseness at connections, check for bends or damage.
  • Tie Rod Ends: Check for excessive wear by grasping and attempting to move.
  • Power Steering: Check pump, hoses, and connections for leaks.
  • Steering Stop: Verify steering stops prevent tire from rubbing.

5 Suspension System

Proper suspension is essential for vehicle stability and load distribution.

  • Springs (Leaf): Look for broken, missing, or shifted leaves.
  • Spring Mounts: Check for cracks in frame at mounting points.
  • Spring Shackles: Check for worn bushings or loose bolts.
  • U-Bolts: All should be present, tight, and not broken.
  • Shock Absorbers: Check mounting and look for leaking fluid.
  • Air Suspension: Check for damaged air bags, listen for leaks.
  • Torque Arms: Check for damage and secure mounting.
  • Track Bars: Ensure secure with no excessive wear at ends.

6 Brake System - Complete Inspection

Critical: Brake defects are the #1 out-of-service violation. Check thoroughly!

Air Brake System Tests

  • Air Compressor: Should build from 50 to 90 psi within 3 minutes at high idle.
  • Governor Cut-out: Should stop pumping between 120-140 psi (typically 125).
  • Air Leakage Test:
    • Build to maximum pressure, turn off engine
    • Release parking brake, apply service brake
    • Hold for one minute - loss should not exceed:
    • Single vehicle: 3 psi/minute
    • Combination vehicle: 4 psi/minute
  • Low Air Warning: Should activate before pressure drops below 60 psi.
  • Spring Brake Test: Continue fanning brakes - parking brake should apply between 20-45 psi.
  • Service Brake Test: At 5 mph, brakes should stop smoothly without pulling.
  • Parking Brake Test: Should hold vehicle on grade without movement.

Brake Components

  • Brake Drums: Check for cracks, damage, or contamination from oil/grease.
  • Brake Shoes: Minimum thickness 1/4 inch at thinnest point.
  • Brake Chambers: Check mounting and look for damaged diaphragms.
  • Slack Adjusters: When pulled by hand, should move less than 1 inch.
  • Push Rods: Check travel - typically should not exceed 2 inches.
  • Air Hoses: Look for cracks, wear, loose fittings, or audible leaks.
  • ABS Light: Should come on at start, then go off - stays off during operation.

7 Wheels and Tires - Complete Inspection

Tires are your only contact with the road - inspect them thoroughly!

Tire Requirements

  • Steer Axle Tires: Minimum tread depth 4/32" - no recaps or regrooves allowed.
  • Drive/Trailer Tires: Minimum tread depth 2/32" - recaps allowed except on steer.
  • Tire Pressure: Check with calibrated gauge - match to load and manufacturer specs.
  • Tire Condition: Look for:
    • Cuts or cracks exposing ply or belt material
    • Bulges or knots indicating separation
    • Uneven wear patterns (alignment/suspension issues)
    • Objects embedded in tread
  • Dual Tires: Should not touch each other, evenly inflated, matched sizes.
  • Valve Stems: Straight, not cracked or damaged, caps in place.

Wheel and Rim Inspection

  • Lug Nuts: All present, no rust trails indicating looseness.
  • Rims: No cracks, bends, or illegal welding repairs.
  • Spacers: If used, must be in pairs and evenly centered.
  • Hub Oil Seals: No leaks - wetness indicates seal failure.
  • Wheel Bearings: No looseness when rocking wheel top to bottom.

8 Lights and Reflectors

Proper lighting ensures you can see and be seen - critical for safety.

  • Headlights: Both high and low beams functioning, properly aimed.
  • Turn Signals: Front and rear, flashing 60-120 times per minute.
  • Hazard Flashers: All four signals working simultaneously.
  • Clearance Lights: Amber front, red rear, at widest points.
  • Side Marker Lights: Amber front, red rear, at regular intervals.
  • Identification Lights: Three red lights at top rear of trailer.
  • Tail Lights: Two working red lights at rear.
  • Brake Lights: Brighter than tail lights when applied.
  • License Plate Light: White light illuminating rear plate.
  • Reflectors: Red rear, amber elsewhere, clean and unbroken.
  • Reflective Tape: If required, red/white pattern on sides and rear.
Final Steps

After completing all inspection points:

  • Complete your Driver Vehicle Inspection Report (DVIR)
  • Report any defects to maintenance immediately
  • Do not operate if any condition affects safety
  • Sign and date your inspection report
  • Keep inspection documentation as required by regulations
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