Illinois Administrative Code › Title 92 - TRANSPORTATION › Part 441 - INSPECTION PROCEDURES FOR TYPE I SCHOOL BUSES › Appendix B - Battery or Batteries through Bumper, Front

Current through Register Vol. 48, No. 28, July 12, 2024
a)
BATTERY OR
BATTERIES
PROCEDURES/SPECIFICATIONS:
One or more batteries may be mounted either in engine
						  compartment or on outside of passenger/driver area. Battery (or batteries
						  together) in a 12 volt system shall be rated, when new, to provide the
						  following:
Engine manufacturer's recommended Cold Cranking Current
						  (amperes for 30 seconds) at -18 degrees C (0 degree F) or, at the purchaser's
						  option, at -29 degrees C (-20 degrees F).
The battery(s) shall provide a Reserve Capacity
						  (duration of 25 ampere current flow) at 27 degrees C (80 degrees F) for no less
						  than 135 minutes.
Low rate discharge capacity of 90 ampere-hours or more
						  (20 hour discharge test at 80 degrees F).
Exception: A bus manufactured in August 1974 or earlier
						  may have a 70 ampere-hour battery, in a 12 volt system.
REJECT VEHICLE IF:
Battery or batteries are not securely mounted;
						  excessively corroded; of insufficient capacity.
b)
BATTERY
CABLES
PROCEDURES/SPECIFICATIONS:
Check condition.
REJECT VEHICLE IF:
Cables are corroded or are not securely
						  attached.
c)
BATTERY
CARRIER
PROCEDURES/SPECIFICATIONS:
When the battery is mounted outside the engine
						  compartment it shall be welded or bolted in a closed, weather-tight, and vented
						  compartment that is located and arranged so as to provide for convenient
						  routine servicing. The battery compartment door, or cover, shall be secured by
						  a manually operated latch or other fastener. A latch or fastener must be
						  designed in such a fashion as to keep the door closed when in the latched
						  position. Each electrical cable connecting the battery in this carrier to the
						  body or chassis shall be one piece between the terminal connector and the first
						  body or chassis terminal connector.
REJECT VEHICLE IF:
Battery carrier does not meet requirements.
d)
BRAKES
PROCEDURES/SPECIFICATIONS:
Every motor vehicle shall be equipped with two separate
						  means of applying the brakes and they shall be so constructed that failure of
						  any one part of the operating mechanism shall not leave the motor vehicle
						  without brakes. (Section 12-301(a) of the Illinois Vehicle Equipment
						  Law)
REJECT VEHICLE IF:
Brakes do not meet requirements.
1)
Backing
Plate
PROCEDURES/SPECIFICATIONS:
Check condition.
REJECT VEHICLE IF:
Backing plate is in poor condition.
2)
Drums/
Discs
PROCEDURES/SPECIFICATIONS:
Inspect drums and/or discs for cracks or for being worn
						  or reworked beyond the manufacturer's minimum limits.
REJECT VEHICLE IF:
Worn or reworked beyond the manufacturer's minimum
						  limits.
3)
Emergency/
Parking
Brake
PROCEDURES/SPECIFICATIONS:
Emergency/parking brake system must apply brakes to at
						  least two wheels. (Section 12-301(a) of the Illinois Vehicle Equipment
						  Law)
AGENCY NOTE:
Micro brakes are not considered a separate means of
						  braking and are not acceptable.
Procedures for testing:
1)
Apply operating control fully.
2)
Check actuating mechanism for release.
Brake Performance Test:
Using Drive-On Pad Type
						  Tester:
1)
Drive vehicle onto brake machine pads at 4-8
						  m.p.h.
2)
Apply emergency/parking brakes to being vehicle to a
						  halt. Do not lock wheels.
3)
Note the braking forces registered by the brake
						  machine.
Using Roll-On Type
						  Tester:
1)
Position axle with emergency brake onto roller.
2)
Apply emergency brake but do not lock wheels.
REJECT VEHICLE IF:
Emergency/parking brakes does not meet
						  requirements.
Procedures for testing:
1)
Not equipped with emergency /parking brakes. Operating
						  mechanism does not hold in the applied position.
2)
Actuating mechanism does not fully release when release
						  control is operated properly.
Brake Performance Test:
Drive-On Tester:
Machine does not register a total braking force of at
						  least 20% of vehicle empty weight. Braking forces at opposite wheels on same
						  axle vary more than 20%.
Roll-On Tester:
Machine does not register a total braking force of at
						  least 20% of vehicle empty weight. Braking forces at opposite wheels on same
						  axle vary more than 20%.
4)
Emergency
Brake
Ratchet
(Pedal or
Lever)
PROCEDURES/SPECIFICATIONS:
Must be in proper adjustment. If vehicle was
						  manufactured with a warning light, it must be visible when emergency brake is
						  activated.
REJECT VEHICLE IF:
Emergency brake ratchet or warning light do not meet
						  requirements.
5)
Pedal
Clearance
(Service
Brakes)
PROCEDURES/SPECIFICATIONS:
Minimum 1 1/2 inch clearance with pedal fully
						  depressed.
REJECT VEHICLE IF:
Pedal clearance does not meet requirements.
6)
Power
Systems
A)
Air
i)
Air Pressure
PROCEDURES/SPECIFICATIONS:
With air system fully charged (compressor governor
						  "cut-out") run engine at low idle. Make one full (maximum) brake application
						  and immediately record reservoir air pressure.
Apply and release brakes until pressure indicated on
						  the air gauge is at least 10 psi (i.e., pounds per square inch) below governor
						  "cut-in" pressure. Run engine at high idle and determine seconds required to
						  raise reservoir pressure from recorded pressure.
REJECT VEHICLE IF:
Time required to raise air pressure from recorded to
						  cut-out is more than 30 seconds. Air gauge is missing or does not
						  operate.
ii)
Low Pressure Warning Device
PROCEDURES/SPECIFICATIONS:
Complete the following steps to evaluate low pressure
						  warning device.
1)
Before starting the engine, apply brakes and release
						  until low air pressure warning device functions.
2)
Start the engine.
3)
Apply service brakes and release until air compressor
						  is activated.
4)
Continue to run engine until compressor cut-out
						  pressure is reached.
5)
Record compressor cut-out pressure.
6)
Shut engine off.
Determine if low pressure warning device is missing or
						  inoperative.
If located in the driver's forward field of view, the
						  warning device can be a visual device only. If not located in the driver's
						  front view, the device must be both audible and visible. For buses manufactured
						  before September 1, 1974, the device can be either audible or visible.
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.
						  Device does not meet requirements.
Low pressure warning device does not operate at 55 psi
						  or one half cut-out pressure, whichever is less.
B)
Electric/
Hydraulic
PROCEDURES/SPECIFICATIONS:
Turn key to "off" position. Depress service brake
						  pedal. Electric hydraulic pump must come "on" (listen).
REJECT VEHICLE IF:
Electric pump does not operate properly or is
						  absent.
C)
Hydraulic
PROCEDURES/SPECIFICATIONS:
Inspect booster belt(s), supports, tubes, hoses,
						  connections, and general condition. Clean reservoir and cover as necessary and
						  check master cylinder fluid level. Do not contaminate fluid.
Turn key to "on" position. Warning signal must come on
						  (look/listen). Depress brake pedal lightly. Start engine. Pedal must move down
						  slightly (feel). Warning signal must go "off" (look/listen).
REJECT VEHICLE IF:
Belt is slack or worn; tube or hose is damaged; any
						  part leaks or is cracked; master cylinder fluid is below manufacturer's
						  recommended capacity.
Either booster or warning signal does not operate
						  properly.
D)
Vacuum/
Hydraulic
PROCEDURES/SPECIFICATIONS:
Inspect tank(s), chambers, hoses, tubes, connectors,
						  clamps, and booster air cleaner.
Inspect supports and attachments.
With engine off, repeatedly apply service brakes until
						  vacuum is depleted, with medium pressure on brake pedal, start engine; release
						  brake and operate engine until maximum vacuum is established; stop engine;
						  apply service brakes hard.
With brakes still applied, start engine; after one
						  minute of running engine, check "Low Vacuum" indicator.
REFJECT VEHICLE IF:
Any component is restricted, collapsed, scraped,
						  cracked, loose, or broken. Booster air cleaner is clogged.
Any support or attachment is broken. Any connecting
						  line or other component is not attached or supported so as to prevent damage
						  from scraping or rubbing.
Foot pedal does not fall away from foot when engine is
						  started; insufficient vacuum reserve to permit one full service brake
						  application after engine is off without actuating "low vacuum" indicator; valve
						  or diaphragm leaking.
7)
Service
Brakes
PROCEDURES/SPECIFICATIONS:
Must be equipped with service brakes on all wheels.
						  (Section 12-301(a)(5) of the Illinois Vehicle Equipment Law)
Must be equipped with a "split system" on service
						  brakes. (
						  49 CFR
						  571.105 )
Power-assisted service braes are required. (
						  49 CFR
						  571.105 )
REJECT VEHICLE IF:
Service brakes do not meet requirements.
A)
Brake
Inspection
Report
PROCEDURES/SPECIFICATIONS:
Verify Brake Inspect Report for following (refer to
						  Section 441.Illustration C for example of form):
1)
Vehicle Identification Number (VIN), make and year must
						  correspond to the bus presented for inspection.
2)
The Brake Inspection Report must indicate the date and
						  mileage at time the brake inspection was performed. If date is more than one
						  year prior to time of inspection or mileage has exceeded 10,000 miles, a brake
						  inspection must be performed.
3)
The form must be completed with all required
						  information. No blank lines are acceptable.
Exception: If the bus has operated less than 10,000
						  miles and less than 12 months have passed since the bus was manufactured, a
						  Brake Inspection Report is not required. Write "Less than 10,000 miles and less
						  than one year old" in the remarks section on the Vehicle Inspection
						  Report.
REJECT VEHICLE IF:
Absent, invalid, or incomplete Brake Inspection
						  Report.
B)
Brake
Performance
Test
PROCEDURES/SPECIFICATIONS:
Using Drive-On Pad Type Brake
						  Tester:
Check vehicle's stopping ability before testing.
Drive vehicle onto brake machine pads at 4-8
						  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.
Using Roll-On Type
						  Tester:
When using roller-type tester each axle must be tested
						  separately. Transmission must be in neutral when testing brakes on any drive
						  axle.
Drive front axle onto rollers. Start roller motor.
						  Apply service brakes but do not lock wheels.
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.
Computerized tester does not register a total braking
						  force of at least 45% of the vehicle empty weight.
Roll-On Tester:
Braking forces at opposite wheels on same axle vary
						  more than 20%.
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%.
e)
BUMPER,
FRONT
PROCEDURES/SPECIFICATIONS:
Either channel type, formed of rolled steel at least
						  .177 inch (4.5 mm)
						  (approximately 
						  3/16
						  inch) thick, or approved energy absorbing type.
Buses manufactured in August 1974 or later must have
						  7.9 inches (200 mm) or more vertical black face.
Bumper must extend to outer edges of fenders and other
						  front end sheet metal. Must be of strength to permit pushing vehicle of equal
						  weight without permanent distortion.
(See CROSSING CONTROL ARM in Section 441.Appendix C for
						  requirements.)
Exception: Buses manufactured prior to September 1974
						  are exempt from bumper thickness and 7.9 inches face requirement.
Exception: For buses that meet the definition of a Type
						  I-A school bus, as defined in Section
						  441.40, the front
						  bumper may meet manufacturer's specifications when the Type I-A school bus is
						  equipped with a driver side air bag.
REJECT VEHICLE IF:
Font bumper does not meet thickness, face height and
						  color requirements. Must be solidly attached, in good condition, free from
						  damage and sharp edges.