Illinois Administrative Code › Title 92 - TRANSPORTATION › Part 438 - INSPECTION PROCEDURES FOR SPECIAL VEHICLES › Appendix A - Battery or Batteries through Exhaust System

Current through Register Vol. 48, No. 28, July 12, 2024
a) BATTERY OR BATTERIES
PROCEDURES/SPECIFICATIONS:
A minimum of one battery must be installed. Two or
				more suitably connected batteries may also be installed.
Battery or batteries must be securely mounted and
				free of excessive corrosion.
REJECT VEHICLE IF:
Battery or batteries are not securely mounted or are
				excessively corroded.
b) BATTERY CABLES
PROCEDURES/SPECIFICATIONS:
Check condition.
REJECT VEHICLE IF:
Cables are corroded or are not securely
				attached.
c) BRAKES
1) SERVICE BRAKES (AIR)
PROCEDURES/SPECIFICATIONS:
Must be equipped with service brakes on all wheels.
				(See IVC Section 12-301(a)(5).)
Service brakes must provide braking action on any
				axle required to have brakes. Application of service brakes could cause the
				vehicle to reduce speed without creating steering problems. All brake
				components must be in good condition. Brake linings or pads must be clean,
				securely attached and of sufficient thickness. There must be no mismatch of air
				chamber sizes and slack adjuster lengths across the steering axle of any power
				unit.
Exception: If the vehicle was manufactured before
				July 25, 1980 and has 3 or more axles, brakes are not required on the front
				wheels. However, if two of those axles are steerable, one of them shall have
				brakes on all wheels.
AGENCY NOTE: Prior to inspecting any components
				located under the vehicle, be sure wheels have been chocked.
Observe braking action while service brakes are
				applied. Inspect for the absence of braking action on any axle required to have
				brakes. An example of absent braking action includes missing brakes or brake
				shoes that fail to move upon application of a wedge, S-cam, cam or disc
				brake.
When the following brake components are visible,
				inspect for good working condition and secure attachment:
Shoes
Lining
Pads
Springs
Anchor Pins
Spiders
Cam Shaft Support Brackets
Cam Rollers
Push Rods (Air Only)
Air Chamber (includes Mounting Bolts) (Air
				Only)
Inspect air brake chamber for any audible air leaks
				(examples include ruptured diaphragm, loose chamber clamp, etc.).
REJECT VEHICLE IF:
Absence of braking action on any axle required to
				have brakes.
Visible brake components are broken or not
				secure.
Audible air leak at brake chamber.
BRAKE PERFORMANCE TEST
PROCEDURES/SPECIFICATIONS:
If Using Drive-On Pad Type Brake Tester:
Check vehicle's stopping ability before
				testing.
Drive vehicle onto brake machine pads at 4 through 8
				m.p.h.
Apply service brakes to bring vehicle to a halt. Do
				not lock wheels.
Note the braking forces registered by the brake
				machine.
If Using Roll-On Type Tester:
Each axle must be tested separately. Transmission
				must be in neutral when testing brakes on any drive axle. Check vehicle's
				stopping ability before testing.
Drive front axle onto rollers and start roller
				motor.
Apply service brakes but do not lock the
				wheels.
Note the braking forces registered by the brake
				machine.
Repeat the above steps for each axle.
The total braking force on a vehicle must be
				determined by adding the results of the test on each axle.
REJECT VEHICLE IF:
Drive-On Tester:
Machine does not register a total braking force of
				at least 60% of the vehicle empty weight. Braking forces at opposite wheels on
				same axle vary more than 20%.
Computerized tester does not register a total
				braking force of at least 45% of the vehicle empty weight.
Roll-On Tester:
Machine does not register a total braking force of
				at least 60% of the vehicle empty weight. Braking forces at opposite wheels on
				same axle vary more than 20%.
2) BRAKE LININGS AND PADS
Inspect brake linings and pads for firm attachment
				to the brake shoe.
Inspect linings and pads for oil, grease or brake
				fluid saturation.
Measure brake linings for minimum thickness:
Air drum brakes - thickness must measure at least
				1/4 inch at the shoe center.
Air disc brakes - thickness must measure at least
				1/8 inch.
Hydraulic brake linings or pad thickness must
				measure more than 1/16 inch.
REJECT VEHICLE IF:
Any brake lining or pad is not securely attached to
				the shoe.
Any brake lining or pad is saturated with oil,
				grease and/or brake fluid.
Brake linings with a thickness less than 1/4 inch at
				the shoe center for air drum brakes; less than 1/8 inch for air disc brakes;
				1/16 inch or less for hydraulic brake linings or pads.
3) AIR CHAMBER SIZE AND SLACK ADJUSTOR LENGTH
PROCEDURES/SPECIFICATIONS:
Inspect the steering axle to determine if air
				chamber sizes and slack adjuster lengths are the same.
REJECT VEHICLE IF:
Air chamber sizes and slack adjuster lengths are not
				the same on the steering axle.
4) PARKING BRAKE SYSTEM
PROCEDURES/SPECIFICATIONS:
Upon actuation of the parking brake control,
				including driveline hand controlled parking brakes, the brakes must be
				activated on the vehicle.
Apply parking brake control and determine if brakes
				have been activated.
REJECT VEHICLE IF:
Brakes on the vehicle are not activated when parking
				brake controls are applied.
Actuating mechanism does not fully release when
				brake control is operated.
5) BRAKE DRUMS OR ROTORS
PROCEDURES/SPECIFICATIONS:
The brake drums and rotors shall be free of cracks
				that open when brakes are applied. The brake drums and rotors shall not have
				any portion missing or in danger of falling away.
Inspect brake drums and rotors for overall integrity
				to identify if any portions are missing or if there are any flexural
				cracks.
AGENCY NOTE: A flexural crack is a crack resulting
				from the drum or rotor being "flexed" at a turn or bend in the metal. Caution
				should be taken to insure that short hairline heat cracks are not confused with
				flexural cracks
REJECT VEHICLE IF:
Any drum or rotor has a portion missing or in danger
				of falling away.
Any flexural crack in the drum or rotor opens when
				the brakes are applied.
6) BRAKE HOSE
PROCEDURES/SPECIFICATIONS:
All brake hoses shall be properly connected and free
				from damage or leaks.
Inspect hose for damage extending through outer
				reinforcement ply.
AGENCY NOTE: Rubber impregnated fabric cover is not
				a reinforcement ply. Thermoplastic nylon may have braid reinforcement or color
				difference between cover and inner tube. Exposure of second color is cause for
				rejection.
Inspect for any bulge or swelling when air pressure
				is applied.
Inspect for any audible leaks.
Inspect for two hoses improperly joined, such as a
				splice made by sliding hose ends over a piece of tubing and clamping hose to
				tube.
Inspect for cracked, broken or crimped hoses.
REJECT VEHICLE IF:
An audible leak is present in brake hoses.
A bulge or swell is present when air pressure is
				applied.
Hoses are cracked, broken or crimped.
7) BRAKE TUBING
PROCEDURES/SPECIFICATIONS:
Brake tubing must be free of leaks and damage from
				heat and must not be cracked, broken or crimped.
Inspect brake lines throughout the vehicle with
				special attention to areas where tubing may be subjected to stress to
				identify:
Any audible leaks;
Cracked tubing;
Tubing damaged by heat; or
Broken or crimped tubing.
REJECT VEHICLE IF:
Brake tubing:
Leaks;
Is damaged from heat; or
Is cracked, broken or crimped.
8) LOW PRESSURE WARNING DEVICE
PROCEDURES/SPECIFICATIONS:
The low pressure warning device must be properly
				installed and in good working condition.
Complete the following steps to evaluate the low
				pressure warning device:
Start the engine.
Apply service brakes and release until air
				compressor is activated.
Continue to run engine until compressor cut out
				pressure is reached.
Record compressor cut out pressure.
Shut off engine.
Apply brakes and release until low air pressure
				warning device functions.
Determine if low pressure warning device (audible or
				visible) is missing or inoperative.
Record the reading found on the pressure gauge at
				which the low pressure warning device functions.
REJECT VEHICLE IF:
Missing or inoperative low pressure warning
				device.
Low pressure warning device does not operate at 55
				psi or one half cut-out pressure, whichever is less.
9) AIR COMPRESSOR
PROCEDURES/SPECIFICATIONS:
Air compressor must be securely mounted with
				brackets, braces or adapters in good order and with the pulley and belts in
				proper condition.
Visually inspect air compressor to identify:
Loose air compressor mounting bolts;
Air compressor mounting brackets, braces or adapters
				that are cracked or broken;
Drive belts in condition of impending or probable
				failure; or
Cracked, broken or loose pulley.
REJECT VEHICLE IF:
Air compressor is not securely mounted.
Mounting brackets, braces or adapters are cracked or
				broken.
Drive belt or belts in condition of impending or
				probable failure.
Pulley is cracked, broken or loose.
10) HYDRAULIC BRAKES (INCLUDING POWER ASSIST OVER
				HYDRAULIC AND ENGINE DRIVE HYDRAULIC BOOSTER)
PROCEDURES/SPECIFICATIONS:
A hydraulic brake system must have a sufficient
				supply of brake fluid. Fluid lines and hoses must be in good working order,
				with no leaks. Components must function as required.
Examine the hydraulic brake system to determine if
				the:
Master cylinder fluid is not below the
				manufacturer's minimum indicator line.
Brake pedal has no reserve when engine is running,
				except by pumping pedal.
Power assist unit fails to operate.
Brake hoses seep or swell with application of brake
				pressure.
Metering valve is missing or inoperative (if vehicle
				is so equipped).
Examine the hydraulic brake system to determine
				if:
A leak is observed in the brake system.
Any brake hose is abraded or chafed through outer
				cover-to-fabric layer.
Any fluid line or connections are leaking,
				restricted, crimped, cracked or broken.
Brake failure or low fluid warning light is on or
				inoperative.
REJECT VEHICLE IF:
Master cylinder fluid is below the manufacturer's
				minimum indicator line.
Brake pedal has no reserve when engine is running,
				except by pumping pedal.
The power assist unit fails to operate.
Brake hoses seep or swell with the application of
				brake pressure.
The metering valve is missing or inoperative (if
				vehicle is so equipped).
A leak is present in the brake system.
Any brake hose is abraded or chafed through outer
				cover-to-fabric layer.
Any fluid line or connections are leaking,
				restricted, crimped, cracked or broken.
Brake failure or low fluid warning light or lights
				are on or inoperative.
11) VACUUM BRAKE SYSTEMS
PROCEDURES/SPECIFICATIONS:
Any vacuum system must have sufficient vacuum
				reserve to permit one full application of brakes after engine is shut off.
				Hoses and lines must be in good condition. Any full vacuum system must be
				equipped with an operative low vacuum warning device.
Determine that sufficient vacuum reserve is present
				after engine is shut off to allow one application of brakes.
Examine hoses and lines. Insure that the lines and
				hoses contain:
No restrictions;
No abrasions (chafing) through outer cover to cord
				ply;
No crimps, cracks or breaks; or
Any area of collapse in the hose when vacuum is
				applied.
Physically examine the low vacuum warning device (if
				vehicle is so equipped) to insure that it is present and operable.
REJECT VEHICLE IF:
Insufficient vacuum reserve for one application of
				brakes.
Any condition listed in the third paragraph above is
				present.
Missing or inoperable low vacuum warning
				devices.
d) BUMPERS
PROCEDURES/SPECIFICATIONS:
Inspect front bumper for secure attachment. Inspect
				rear bumper, if vehicle is so equipped. (See Section 438.20 for definition of
				bumper.)
Exception: Vehicles with a GVWR of more than 9,000
				lbs. are exempt from having a rear bumper. (See Section 12-608(a) of the
				Illinois Vehicle Equipment Law.)
REJECT VEHICLE IF:
The front bumper is missing or loosely attached. If
				vehicle is required to have a rear bumper, it is missing or loosely
				attached.
e) DOORS
PROCEDURES/SPECIFICATIONS:
If vehicle is equipped, inspect door latches and
				handles for proper operation.
REJECT VEHICLE IF:
The door does not operate properly (if the vehicle
				is so equipped).
f) EXHAUST SYSTEM
PROCEDURES/SPECIFICATIONS:
If vehicle is so equipped, inspect the manifold,
				muffler, resonator, all pipes, gaskets and supporting hardware.
The exhaust system must be located outside the
				vehicle's body and attached securely to the vehicle.
The exhaust system must not leak and must discharge
				outside the perimeter of the vehicle's body or must meet manufacturer's
				original design.
REJECT VEHICLE IF:
Any part of the system is not securely
				supported.
Any part of the system is leaking.
Any part of the system contains holes not made by
				manufacturer.
Any part of the system passes through the passenger
				compartment.
Exhaust discharge does not exit outside the
				perimeter of the vehicle's body or does not meet manufacturer's original
				design.
Any exposed exhaust stack does not have a protective
				shield or insulated lining to prevent burns.