Virginia Administrative Code › Title 19 - PUBLIC SAFETY › Agency 30 - DEPARTMENT OF STATE POLICE › Chapter 70 - MOTOR VEHICLE SAFETY INSPECTION REGULATIONS › Part V - Inspection Requirements for Trucks and Other Vehicles Over 10,000 Pounds (GVWR) › Section 19VAC30-70-440 - Service brakes

Current through Register Vol. 40, No. 24, July 15, 2024
A. The
				  inspector, at a minimum, must drive all vehicles into the inspection lane and
				  test both service and parking brakes, except vehicles the inspector is not
				  qualified to drive. In these cases, the inspector will ride in the vehicle and
				  observe the application of the brakes.
B. A minimum of one wheel or one wheel and
				  drum or dust cover must be removed from each vehicle at the time of inspection
				  except vehicles having open brake mechanisms that will permit the inspection of
				  the brake lining, or discs and disc pads, without removing the wheel and rim.
WARNING: Failure to properly torque lug nuts may cause
					 severe damage to the wheel.
The inspection receipt (approval and rejection) shall be
					 marked to reflect which wheel and drum or dust cover was removed or
					 inspected.
C. If any braking
				  problem is detected, the inspector may test drive or require a test drive of
				  the vehicle.
D. Inspect for and
				  reject if:
1. Any commercial motor vehicle
				  manufactured on or after October 20, 1994, is equipped with an air brake system
				  but is not equipped with the proper and functioning automatic brake adjuster
				  system and brake adjuster indicator.
2. Vehicles equipped with air brakes: when
				  the air brake adjustment on vehicles is equal to or exceeds values in the
				  following tables for cam brakes or brake shoe travel is greater than 1/16" on
				  wedge brakes when measured according to Illustrations #1 and #2. (See procedure
				  in addition to illustrations.)
TABLE 1 MINIMUM CRITERIA FOR BRAKE
								  ADJUSTMENT COMMERCIAL VEHICLE SAFETY ALLIANCE NORTH AMERICAN STANDARD
								  OUT-OF-SERVICE CRITERIA
Brake adjustment shall not exceed
								  those specifications contained hereunder relating to "Brake adjustment limit."
								  (Dimensions are in inches.)
CLAMP TYPE BRAKE CHAMBER
								  DATA
Type
Outside Diameter
Brakes Exceeding the Maximum Brake Adjustment
								  Limit Shall be Readjusted
6
4-1/2 (114mm)
1-1/4 (32mm)
9
5-1/4 (133mm)
1-3/8 (35mm)
12
5-11/16 (145mm)
1-3/8 (35mm)
16
6-3/8 (162mm)
1-3/4 (45mm)
20
6-25/32 (172mm)
1-3/4 (45mm)
24
7-7/32 (184mm)
1-3/4 (45mm)
30
8-3/32 (206mm)
2.0 (51mm)
36
9.0 (229mm)
2-1/4 (57mm)
NOTE: A brake found at the adjustment limit is
								  not to be rejected.
LONG STROKE CLAMP TYPE BRAKE
								  CHAMBER DATA
Type
Outside Diameter
Brakes Exceeding the Maximum Brake Adjustment
								  Limit Shall be Readjusted
12
5-11/16 (14.5mm)
1-3/4 (45mm)
16
6-3/8 (162mm)
2.0 (51mm)
20
6-25/32 (172mm)
2.0 (51mm)
24
7-7/32 (184mm)
2.0 (51mm)
24*
7-7/32 (184mm)
2.5 (64mm)
30
8-3/32 (206mm)
2.5 (64mm)
*For 3" maximum stroke type 24 chambers
NOTE: A brake found at the adjustment limit is
								  not to be rejected.
NOTE: 3" long stroke brake chambers are
								  identified by square air line ports and a trapezoidal tag attached to the
								  chamber.
BOLT TYPE BRAKE CHAMBER
								  DATA
Type
Outside Diameter
Brakes Exceeding the Maximum Brake Adjustment
								  Limit Shall be Readjusted
A (12)
6-15/16 (176mm)
1-3/8 (35mm)
B (24)
-3/16 (234mm)
1-3/4 (45mm)
C (16)
8-1/16 (205mm)
1-3/4 (45mm)
D (6)
5-1/4 (133mm)
1-1/4 (32mm)
E (9)
6-3/16 (157mm)
1-3/8 (35mm)
F (36)
11.0 (279mm)
2-1/4 (57mm)
G (30)
9-7/8 (251mm)
2.0 (51mm)
NOTE: A brake found at the adjustment limit is
								  not to be rejected.
ROTOCHAMBER DATA
Type
Outside Diameter
Brakes Exceeding the Maximum Brake Adjustment
								  Limit Shall be Readjusted
9
4-9/32 (109mm)
1-1/2 (38mm)
12
4-13/16 (122mm)
1-1/2 (38mm)
16
5-13/32 (138mm)
2.0 (51mm)
20
5-15/16 (151mm)
2.0 (51mm)
24
6-13/32 (163mm)
2.0 (51mm)
30
7-1/16 (180mm)
2-1/4 (57mm)
36
7-5/8 (194mm)
2-3/4 (70mm)
50
8-7/8 (226mm)
3.0 (76mm)
NOTE: A brake found at the adjustment limit is
								  not to be rejected.
DD-3 BRAKE CHAMBER DATA
Type
Outside Diameter
Brakes Exceeding the Maximum Brake Adjustment
								  Limit Shall be Readjusted
30
8-1/8 (206mm)
2-1/4 (57mm)
NOTE: This chamber has three air lines and is
								  found on motor coaches.
NOTE: A brake found at the adjustment limit is
								  not to be rejected.
WEDGE BRAKE DATA
The combined movement of both brake shoe lining
								  scribe marks shall not exceed 1/8 inch (3.18mm).
PROCEDURE FOR MEASURING CAM AND WEDGE BRAKES AND HOW TO
					 PROPERLY IDENTIFY 3" LONG STROKE CHAMBERS
On vehicles equipped with cam brakes, mark each brake
					 chamber push rod at the face of the brake chamber with the brakes released.
					 Apply the air brakes fully, minimum air pressure of 90 to 100 psi, and measure
					 the distance the push rod travels from the face of the chamber to the mark
					 previously made when the brakes were released. This measurement is the push-rod
					 stroke (see illustration).
On vehicles equipped with wedge brakes, remove the
					 inspection hole cover at each dust shield and with the brakes released, scribe
					 a line on the edge of the brake lining. Apply the air brakes fully and measure
					 the distance the brake lining travels.
Click here to view
					 image
Click here to view
					 image
Click here to view
					 image
3. Brake
				  hose and tubing. There is any leakage in any hydraulic, air or vacuum lines;
				  hoses have any cracks, crimps, restrictions, or are abraded exposing fabric
				  into second ply of fabric; tubing or connections leak, are crimped, restricted,
				  cracked, or broken.
a. Hose with any damage
				  extending through the reinforcement ply. 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.
b. Bulge or swelling
				  when air pressure is applied.
c.
				  Two hoses improperly joined (such as a splice made by sliding the hose ends
				  over a piece of tubing and clamping the hose to the tube).
d. Brake tubing and hose must:
(1) Be long and flexible enough to
				  accommodate without damage all normal motions of the parts to which it is
				  attached;
(2) Be secured against
				  chaffing, kinking, or other mechanical damage; and
(3) Be installed in a manner that prevents it
				  from contacting the vehicle's exhaust system or any other source of high
				  temperatures.
e. Any
				  hydraulic brake tubing has been repaired using a compression
				  fitting.
4. Service
				  brakes.
a. There is less than 1/5 reserve in
				  pedal travel of the service brake when fully applied on all hydraulic,
				  mechanical, or power-assisted hydraulic braking systems.
b. When tested on dry, hard, approximately
				  level road free from loose material at a speed of 20 miles per hour without
				  leaving a 12-foot wide lane, a distance in excess of the following stopping
				  distance is obtained:
Any bus, truck or tractor - 40 feet;
All combinations of vehicles - 40 feet.
c. Every motor vehicle, trailer or
				  semitrailer is not equipped with operational brakes on all wheels (except as
				  shown in subdivision D 4 c (1) of this section) or any brake has been
				  disconnected or rendered inoperative or improperly installed.
(1) Road tractors, tractor trucks, or trucks
				  if manufactured prior to July 25, 1980, having three or more axles are not
				  required to have brakes on the steering axle; however, if installed must be
				  inspected and meet all requirements of this section.
(2) Missing, bent or broken mechanical
				  components including: shoes, lining pads, spring, anchor pin, spiders, cam
				  rollers, push rods and air chamber mounting bolts, air reservoirs not securely
				  mounted or leaks.
(3) Absence of
				  braking action on any axle required to have brakes, upon application of the
				  service brakes (such as missing brakes or brake shoes, failing to move upon
				  application of a wedge, S-cam or disc brake).
(4) Loose brake components including air
				  chambers, spiders and cam shaft support brackets.
(5) Audible air leak at brake chamber
				  (example: ruptured diaphragm, loose chamber clamp, etc.)
d. Linings or pads are broken or cracked so
				  that brake pad is not firmly attached to the shoe or improperly installed or
				  cracks on the friction surface extends to the open edge.
(1) Rivets or bolts are loose or
				  missing.
(2) Lining or pad friction
				  surface is saturated with oil, grease or brake fluid.
e. Nonsteering axles. Lining has a thickness
				  less than 1/4 inch at the shoe center for air drum brakes, 1/16 inch or less at
				  the shoe center for hydraulic and electric drum brakes and less than 1/8 inch
				  for air disc brakes, lining with a thickness less than 3/16 inch for a shoe
				  with a continuous strip of lining or to wear indicators if so equipped.
(1) Steering axles. Lining has thickness less
				  than 1/4 inch at the shoe center from drum brakes, less than 1/8 inch for air
				  disc brakes and 1/16 inch or less for hydraulic disc and electric brakes,
				  lining with a thickness less than 3/16 inch for a shoe with a continuous strip
				  of lining or to wear indicators if so equipped.
(2) Mismatch across any power unit steering
				  axle of:
(a) Air chamber sizes.
(b) Slack adjuster length.
f. Thickness of riveted
				  or bolted lining is less than 2/32 of an inch above the rivet or bolt
				  head(s).
g. Any lining or pad is
				  misaligned or does not make full contact with the drum or rotor.
5. Brake Drums and Discs.
a. Brake drums or brake discs (rotors) are
				  worn or scored to the extent that their remachining would result in a failure
				  to meet manufacturer's specifications.
b. Brake drums or discs with any external
				  crack or cracks that open upon brake application.
NOTE: Do not confuse short hairline heat cracks with
					 flexural cracks.
6. Mechanical linkage.
Any portion of the drum or rotor missing or in danger of
					 falling away.
7. Hydraulic.
NOTE: Some motor vehicles, beginning with 1976 models,
					 have a hydraulic power system that serves both the power assisted brakes and
					 power assisted steering system. Some vehicles, beginning with 1985 models, have
					 an integrated hydraulic actuation and anti-lock brake unit using only brake
					 fluid.
8. Hydraulic System
				  Operation.
Stop engine, then depress brake pedal several times to
					 eliminate all pressure. Depress pedal with a light foot-force (30 pounds).
					 While maintaining this force on the pedal, start engine and observe if pedal
					 moves slightly when engine starts.
Reject vehicle if pedal does not move slightly as engine is
					 started while force is on brake pedal.
Click here to view
					 image
9. Condition of
				  hydraulic booster power brake system.
Inspect system for fluid level and leaks. Reject vehicle
					 if there is insufficient fluid in the power steering pump reservoir; if there
					 are broken, kinked or restricted fluid lines or hoses; if there is any leakage
					 of fluid at the pump, steering gear or brake booster, or any of the lines or
					 hoses in the system; or if belts are frayed, cracked or excessively
					 worn.
10. Integrated
				  hydraulic booster/anti-lock system operation.
With the ignition key in the off position, depress brake
					 pedal a minimum of 25 times to deplete all residual stored pressure in the
					 accumulator. Depress pedal with a light foot-force (25 lbs.). Place ignition
					 key in the on position and allow 60 seconds for the brake warning light to go
					 out and the electric pump to shut off.
Reject vehicle if the brake pedal does not move down
					 slightly as the pump builds pressure or if the brake and anti-lock warning
					 lights remain on longer than 60 seconds.
Click here to view
					 image
11.
				  Condition of integrated hydraulic booster/anti-lock system with electronic
				  pump.
With the system fully charged, inspect system for fluid
					 level and leaks.
Reject vehicle if there is insufficient fluid in the
					 reservoir; if there are broken, kinked or restricted fluid lines or hoses; or
					 if there is any leakage of fluid at the pump or brake booster, or any of the
					 lines or hoses in the system.
12. Vacuum system operation.
Stop engine then depress brake pedal several times to
					 eliminate all vacuum in the system. Depress pedal with a light foot-force (25
					 lbs.). While maintaining this force on the pedal, start engine and observe if
					 pedal moves down slightly when engine starts.
Reject vehicle if pedal does not move down slightly as
					 engine is started while force is on the brake pedal. In full vacuum-equipped
					 vehicles, there is insufficient vacuum reserve for one full service brake
					 application after engine is stopped.
a. Has insufficient vacuum reserve to permit
				  one full brake application after engine is shut off.
b. Lacks an operative low-vacuum warning
				  device as required.
Click here to view
					 image
13. Condition of vacuum booster power brake
				  system.
a. Visual inspection. Reject vehicle
				  if there are collapsed, cracked, broken, badly chafed or improperly supported
				  hoses and tubes, loose or broken hose clamps.
b. There is any leakage in the hydraulic
				  system. (Do not disturb the dust boot when checking for leaking wheel
				  cylinders.)
c. Fluid level in
				  master cylinder is below the proper level for the particular vehicle.
d. There is any evidence of a caliper
				  sticking or binding.
14.
				  Air brakes.
a. Motor vehicle is equipped with
				  air brakes and does not have an operating air pressure gauge.
b. Any bus, truck, road tractor and tractor
				  truck manufactured after March 15, 1975, must have a visible low air warning
				  device. Those manufactured on or before March 15, 1975, may have either an
				  audible or visible low air warning device.
Low pressure warning device is missing, inoperative or
					 does not operate at 55 psi and below or 1/2 the governor cut out pressure,
					 whichever is less.
c.
				  Compressed air reserve is not sufficient to make one full service brake
				  application after engine is stopped, or with system fully charged, the
				  reservoir pressure is lowered more than 30% by one full brake application.
Brake chamber push rods do not follow application of
					 service brake pedal, or do not reach full released position (example: defective
					 return spring).
d. Any bus,
				  truck, road tractor, or tractor truck manufactured after February 28, 1975, if
				  equipped with a manually operated device to reduce or remove the braking effort
				  upon its front wheels.
15. Electric brakes.
a. Trailers show an amperage value more than
				  20% above or 30% below the brake manufacturer's maximum current rating for each
				  brake.
b. Ammeter shows no reading
				  or indicator is not steady on application and release of brake
				  controller.
c. Any terminal
				  connections are loose or dirty; wires are broken, frayed or unsupported; any
				  single conductor or nonstranded wire or wires below size recommended by brake
				  manufacturers are installed.
d.
				  Electrical trailer brakes do not apply automatically when breakaway safety
				  switch is operated.
e. Absence of
				  braking action on any wheel required to have brakes.
f. Missing or inoperative breakaway braking
				  device; cable is frayed or broken.
16. Air compressor.
a. Compressor drive belts are in condition of
				  impending or probable failure.
b.
				  Loose compressor mounting bolts or compressor leaks.
c. Cracked, broken or loose pulley.
d. Tractor protection valve(s) is defective
				  or inoperative.
e. Air safety
				  relief valve is defective or inoperative.