comprehensive-inspection-guidelines-v1

8/7/2019 comprehensive-inspection-guidelines-v1

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Manual for the Categorisation ofDefects on Heavy Motor Vehicles

Comprehensive InspectionGuidelines Version 1


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05/05/05

Categorisation of Defects Project

Comprehensive Inspection Version 1

Comprehensive Inspection Guidelines Version 1

PREAMBLE

Section 115 of the Land Transport Act 1998 (Act) empowers enforcement officers to direct that a vehicle must not be used on a road. The following areguidelines to assist with the more consistent application of the section.

This aid has been developed to assist enforcement officers in determining in or out of service criteria for vehicles found with defects on the roadside.

It should be noted that the pass/fail criteria can differ from that applied to the vehicle at the time of COF issuance.

It applies criteria, which will assist in consistency of application when assessing if a vehicle is safe to continue after a Walk-Around Inspection.

Depending on the fault/s identified, and the particular circumstances, an out-of-service-order may be issued, with an accompanying pink or green sticker.A police officer also has an alternative option of issuing an offence notice with an instruction for repair or rectification of the fault/s to be carried out

within a specified time.

Failure to comply with the instruction on an offence notice to repair or rectify the fault/s, and to notify the Police that the faults have been remedied, mayresult in prosecution.

Driver is to be advised the level of assessment prior to commencement of inspection. (eg walk-around or comprehensive)

DISCRETIONARY EQUIPMENT Checking of towing connections is with appropriate equipment (go no go gauge) is discretionary Note: If trailer disconnected it is to be

made clear to the driver that it is his/her responsibility to ensure a safe recoupling (including air lines) before moving off.

Use of the Heat Gun for assessing brake drum temperatures is discretionary and should an enforcement officer decide to carry out thischeck then the attached procedure, developed by the Police should be referred to. LINK.

INTERPRETATION

*Loose Visually or can be moved without the aid of a tool

*Codes - QP (Qualifies for Pink)*Codes - QG (Qualified for Green)


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Contents

1. Lighting and signalling.............................................................................. 3

1.1 Headlamps ........................................................................................ 31.2 Side lamps......................................................................................... 51.3 Direction indicator lamps (incl. repeaters) ......................................... 61.4 Stop lamps (incl. aux. stop lamps)..................................................... 71.5 Rear reflectors................................................................................... 81.6 Registration plate lamps.................................................................... 91.7 Auxiliary headlamps .......................................................................... 91.8 Spot lamps ...................................................................................... 111.9 Cornering lamps.............................................................................. 111.10 Reversing lamps.............................................................................. 121.11 Daytime running lamps.................................................................... 121.12 Side marker lamps........................................................................... 13

1.13 Cab roof lamps ................................................................................ 131.14 Scene lamps.................................................................................... 141.15 Flashing or revolving lamps............................................................. 15

2. Vision........................................................................................................ 16

2.1 Glazing, incl. windscreens ............................................................... 162.2 Windscreen wipe and wash systems............................................... 172.3 Rear-view mirrors ............................................................................ 18

2.4 Television sets................................................................................. 192.5 Drivers sun visor............................................................................. 19

3. Brakes....................................................................................................... 20

3.1 Brakes, general ............................................................................... 203.2 Driver controls ................................................................................. 213.3 Pipes, hoses and connectors .......................................................... 22

3.4 Linkages and mechanisms.............................................................. 233.5 Air compressors and vacuum pumps .............................................. 253.6 Actuators, valves and reservoirs ..................................................... 263.7 Drums, discs, shoes and pads ........................................................ 273.8 Compressed air system capacity..................................................... 283.9 System protection and instrumentation ........................................... 293 10 S i b k 30


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5. Occupant safety....................................................................................... 41

5.1 Vehicle structural strength and condition......................................... 415.2 PSV electrical requirements ............................................................ 425.3 Entrance and doors ......................................................................... 425.4 PSV entry and exit steps, and ramps .............................................. 435.5 Seats, general ................................................................................. 445.6 PSV seating..................................................................................... 45

5.7 PSV passenger compartment.......................................................... 465.8 PSV drivers seat and vision............................................................ 475.9 PSV emergency exits ...................................................................... 485.10 PSV fire extinguishers and fire protection........................................ 495.11 PSV passenger signals ................................................................... 505.12 PSV towing and tow bars ................................................................ 505.13 PSV load security ............................................................................ 505.14 PSV roof racks ................................................................................ 515.15 PSV ventilation................................................................................ 515.16 PSV demisters................................................................................. 52

6. External safety ......................................................................................... 53

6.1 Mudguards ...................................................................................... 536.2 Exhaust system ............................................................................... 536.3 External projections......................................................................... 54

7. Load restraints and towing connections............................................... 55

7.1 Load anchorages, general............................................................... 557.2 Bolster attachments......................................................................... 567.3 Drawbeams ..................................................................................... 577.4 Drawbars and ballrace turntables.................................................... 587.5 Fifth wheels and kingpins ................................................................ 59

8. Miscellaneous .......................................................................................... 61

8.1 Speedometer ................................................................................... 618.2 Audible warning devices.................................................................. 618.3 Fuel system (incl. alternative fuel system)....................................... 628.4 Vehicle dimensions.......................................................................... 63


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Code Inspection item and description of defect Severity of defect(if applicable) and defect category Notes

05/05/05 4Categorisation of Defects Project


LHU

LHS

LHY

LHI

Condition(k) A headlamp is not securely fitted

(l) A headlamp is damaged, e.g. the lens is damaged ormissing, water is in the lamp, or the reflector is

deteriorated

(m) A headlamp is obscured5

(n) A headlamp is partially or fully fitted with a cover that is

opaque, tinted, damaged or deteriorated

(i) A vehicle is operated during the hours ofdarkness and detachment of all headlamps isimminent................................................................

(ii) Detachment is imminent under conditions otherthan (i) ...................................................................

(iii) Other than above ..................................................(i) The lamps light output or pattern is affected or

water is in the lamp (failure of the lamp is

imminent e.g. a lens is missing or significantlydamaged) ..............................................................(ii) Other than above ..................................................(i) Fully obscured.......................................................(ii) Partially obscured..................................................(iii) Fully or obscured (Day).........................................(i) The lamps light output or pattern is affected

(Night)....................................................................(ii) Other than above (Day).........................................

P

GY

GY

PGY

GY

5Obscured, for example, by a bullbar.


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1.2 Side lampsRearLMY

LMO

LMY3

LMY2

GeneralLMM

LMU

LMY

LMY

(a) A required side lamp is not fitted

(b) A side lamp is not operational, works intermittently,flashes, or flickers when tapped.

(c) A rear side lamp emits light of a colour other than redor rear side lamp is obscured

(d) A front side lamp emits light of a colour other thanwhite or amber (but is not red)

(e) A side lamp is not securely fitted

(f) A side lamp is damaged, e.g. the lens is damaged ormissing, water is in the lamp, or the reflector isdeteriorated

(g) A side lamp is obscured

(h) A side lamp is partially or fully fitted with a cover that isopaque, tinted, damaged or deteriorated

(i) A vehicle is operated during the hours ofdarkness with no rear side lamps fitted.................

(ii) No right side rear tail lamp working during thehours of darkness and no other rear right sidelamp operational below 2 meters ..........................

(iii) Other than above ..................................................

(i) A vehicle is operated during the hours ofdarkness with no rear side lamp fully operational.

(ii) Other than above ..................................................

(i) Fully obscured (Night) ............................................(ii) Partially Obscured..................................................(iii) Other .....................................................................

.....................................................................................

(i) Detachment is imminent........................................(ii) Other than above ..................................................(i) The lamps light output is affected, or failure of

the lamp is imminent (e.g. a lens is missing orsignificantly damaged, or water is in the lamp) .....

(ii) Other than above ..................................................(i) Fully obscured.......................................................(ii) Partially obscured..................................................(i) The lamps light output is affected (Night).............(ii) Other than above ..................................................

P

PG

PG

PYY

Y

G

Y

GY

GY

GY


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1.4 Stop lamps (incl. aux. stop lamps)

LSF

LSO

LSY

LSO

LSY

LSU

LSY

LSY

LSY

(a) A required stop lamp is not fitted

(b) A stop lamp does not operate when the service brakeis applied

(c) A stop lamp operates when the service brake is notapplied

1

(d) A stop lamp works intermittently, flashes, or flickerswhen tapped

1

(e) A stop lamp emits light of a colour other than red1

(f) A stop lamp is not securely fitted1

(g) A stop lamp is damaged, e.g. the lens is damaged ormissing, water is in the lamp, or the reflector isdeteriorated

(h) A stop lamp is obscured

(i) A stop lamp is partially or fully fitted with a cover that isopaque, tinted, damaged or deteriorated

(i) No required stop lamp is fitted ..............................(ii) Only one of two required stop lamps is fitted........(i) All required stop lamps are affected .....................(ii) At least one required stop lamp is not affected

and works normally ...............................................

(i) All stop lamps are affected....................................(ii) At least one required stop lamp is not affected


(i) All stop lamps are affected....................................(ii) At least one required stop lamp is not affected


......................................................................................(i) Detachment is imminent........................................(ii) Other than above ..................................................

(i) The lamps light output is affected ........................(ii) Failure of the lamp is imminent (e.g. a lens is

missing or significantly damaged, or water is inthe lamp) ...............................................................(iii) Other than above ..................................................(i) Fully obscured.......................................................(ii) Partially obscured..................................................

(i) The lamps light output is affected ........................

PG

G

Y

G

Y

G

Y

Y

GY

Y

GY

GY

Y

1Applies also to auxiliary stop lamps(defects without reference to thisnote do not apply to auxiliary stop

lamps).


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1.5 Rear reflectors

LRFS

LRF

LRY

LRU

LRS

LRY

LRY

(j) Right hand reflector is missing or ineffective duringhours of darkness

(k) A required rear reflector is not fitted

(i) A rear reflector reflects light of a colour other than red

(j) A rear reflector is not securely fitted

(k) A rear reflector is damaged or not clean

(l) A rear reflector is partially or fully obscured

(m) A rear reflector is partially or fully fitted with a cover thatis opaque, tinted, damaged or deteriorated

......................................................................................(i) No required reflector is fitted.................................(ii) Only one of two required reflectors is fitted.................................................................................................

......................................................................................

......................................................................................

(i) Night......................................................................(ii) Day........................................................................

......................................................................................

P

GG

Y

Y

Y

GY

Y


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1.6 Registration plate lamps

LNF

LNO

LNY

LNY

LNU

LNY

LNY

(a) A required registration plate lamp is not fitted

(b) A registration plate lamp is not operational, worksintermittently, flashes, or flickers when tapped

(c) A registration plate lamp emits light of a colour otherthan white

(d) A registration plate lamp is directly visible from the rear(e) A registration plate lamp is not securely fitted

(f) A registration plate lamp is damaged, e.g. the lens is

damaged or missing, water is in the lamp, or thereflector is deteriorated

(g) A registration plate lamp is obscured

......................................................................................

......................................................................................

......................................................................................

............................................................................................................................................................................

............................................................................................................................................................................

G

Y

Y

Y

Y

Y

Y

1.7 Auxiliary headlamps

LAF

LAF

Fitting(a) Only one (front), or more than two (front or rear), fog

lamp(s) is/are fitted

(b) Only one, or more than two, auxiliary high beamheadlamp(s) is/are fitted

(c) A fog lamp to the rear is not red

(d) A front fog lamp is not dipped

......................................................................................

......................................................................................

............................................................................................................................................................................

G

G

G

Y


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1.8 Spot lamps

LDF

LDY

LOU

(a) More than one spot lamp is fitted

(b) A spot lamp emits light of a colour other than white oramber

(c) A spot lamp is not securely fitted

..............................................................................................

..............................................................................................

(i) Detachment is imminent........................................(ii) Other than above ..................................................

Y

Y

Y

Y

1.9 Cornering lamps

LOF/LIF

LIO/LOD

LIY

LOA

LOY

LOY

LOF

(a) Only one, or more than two, cornering lamp(s) is/arefitted

(b) A cornering lamp works intermittently, flashes, or

flickers when tapped

(c) A cornering lamp operates with the headlampsswitched off, without the direction indicators on thesame side operating, or with the direction indicators onthe opposite side operating

(d) A cornering lamp emits a light other than white oramber

(e) A cornering lamp emits light of a colour other thanwhite or amber

(f) A cornering lamp is directly visible from the rear

(g) A cornering lamp is not securely fitted

..............................................................................................

..............................................................................................

..............................................................................................

......................................................................................

..............................................................................................

..............................................................................................


Y

Y

Y

G

Y

Y

G

Y


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1.10 Reversing lamps

LBY

LBO

LBO

LBF

(a) More than two reversing lamps are fitted

(b) A reversing lamp works intermittently, flashes, orflickers when tapped

(c) A reversing lamp operates without the reverse gearengaged or, if switched independently of the reverse

gear

(d) A reversing lamp is not white in colour

..............................................................................................

..............................................................................................

..............................................................................................

(i) Other than above.......................................................

Y

Y

G

Y

1.11 Daytime running lamps

LOY

LOY

LDO

LOY

LOF

(a) Only one, or more than two, daytime running lamp(s)

is/are fitted

(b) A daytime running lamp is not fitted at the front of thevehicle or does not face forward

(c) A daytime running lamp works intermittently, flashes,or flickers when tapped or operates with fog lights

(d) A daytime running lamp emits light of a colour other

than white or amber

(e) A daytime running lamp is not securely fitted

..............................................................................................

..............................................................................................

..............................................................................................

..............................................................................................


G

Y

Y

Y

G

Y

Group A or T vehicles not to havedaytime running lamps (DTR).


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1.12 Side marker lamps

LMY2

LMY2

LMO2

LMY2

LMU2

LMS2

LMY2

LMY2

(a) A required side marker lamp is not fitted

(b) A side marker lamp is not fitted at approx. 1/3 of thevehicles length from the rear

(c) A side marker lamp is not operational, worksintermittently, flashes, or flickers when tapped

(d) A side marker lamp emits light of a colour other thanwhite or amber to the front; or red or amber to the rear

(e) A side marker lamp is not securely fitted

(f) A side marker lamp is damaged, e.g. the lens isdamaged or missing, water is in the lamp, or the

reflector is deteriorated

(g) A side marker lamp is obscured

(h) A side marker lamp is partially or fully fitted with acover that is opaque, tinted, damaged or deteriorated

......................................................................................

......................................................................................

......................................................................................

......................................................................................(i) Detachment is imminent........................................(ii) Other than above ..................................................(i) The lamps light output is affected, or failure of

the lamp is imminent (e.g. a lens is missing or

significantly damaged, or water is in the lamp) .....(ii) Other than above ..................................................(i) Fully obscured (Night only) ...................................(ii) Partially obscured..................................................(i) The lamps light output is affected ........................(ii) Other than above ..................................................

G

Y

Y

Y

GY

YY

GY

Y

Y

1.13 Cab roof lamps

LOY

LOO

LOY

(a) A required cab roof lamp is not fitted

(b) A cab roof lamp is not operational, works intermittently,flashes, or flickers when tapped

(c) A cab roof lamp emits light of a colour other than

amber

......................................................................................

......................................................................................

......................................................................................

G

Y

Y


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LOF

LOS

LOY

LOY

(d) A cab roof lamp is not securely fitted

(e) A cab roof lamp is damaged, e.g. the lens is damagedor missing, water is in the lamp, or the reflector isdeteriorated

(f) A cab roof lamp is partially or fully obscured

(g) A cab roof lamp is partially or fully fitted with a coverthat is opaque, tinted, damaged or deteriorated

(i) Detachment is imminent........................................(ii) Other than above ..................................................(i) The lamps light output is affected, or failure of

the lamp is imminent (e.g. a lens is missing orsignificantly damaged, or water is in the lamp) .....

(ii) Other than above ........................................................................................................................................(i) The lamps light output is affected ........................(ii) Other than above ..................................................

GY

YY

Y

YY

1.14 Scene lamps

LOY

LOY

LOF

LOY

(a) A scene lamp is fitted to a vehicle other than a heavygoods vehicle, forklift, ambulance or fire appliance

(b) More than two scene lamps are fitted to a heavy goodsvehicle, or more than four scene lamps are fitted to anambulance or fire appliance

(c) A scene lamp is not securely fitted

(d) A warning light which indicates operation of a scene

lamp to the driver is not fitted or not operational

......................................................................................

......................................................................................(i) Detachment is imminent........................................(ii) Other than above ..................................................

......................................................................................

Y

Y

GY

Y


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2. Vision2.1 Glazing, incl. windscreens

IWY

LWY

LWY

LWA

IWI

IWS

IWS

Fitting(a) A piece of glazing does not comply with an approved

standard or trade name

(b) A windscreen is not made of laminated glass, or anyother piece of glazing is not made of safety glass

(c) A windscreen has a VLT of


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IWY

IWY

IWY

(h) A modification to a piece of glazing does not complywith applicable requirements

(i) A wire mesh windscreen stone guard extends higherthan the top of the steering wheel, its mesh size is lessthan 12mm, or there is no space between the stoneguard and the windscreen

(j) An overlay is applied along lower edge of windscreenabove the highest point of the steering wheel in theuppermost position

(i) A windscreen is fitted with a tinted overlay thatreduces the overall VLT to


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2.4 Television sets

ITY (a) A television set is fitted where it is directly visible to thedriver and, while the vehicle is in motion, the set canbe used for purposes other than providing a view tothe rear of the vehicle, navigation, or safe operationand control of the vehicle; or screen only displays textand any change is controlled manually by driver; orPSV Rule complied with in a PSV ......................................................................................

G

2.5 Drivers sun visor

IVF

IUO

IVU

IVY

(a) A required sun visor is not fitted

(b) A sun visor is not operational

(c) A sun visor is not securely fitted

Additional to PSVs(d) A sun visor cannot be adjusted from the drivers seat

......................................................................................(i) Must be effective..................................................(i) Detachment is imminent........................................


......................................................................................

G

G

G

Y

Y


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BPY1

BEI1

BRI1

Park brake and emergency brake(d) A lever is missing or not operational or does not lock

into position an remain permanent applied

(e) A lever is not securely fastened

(f) There is excessive lever travel

......................................................................................(i) Detachment is imminent or there is a risk of the

brake being released inadvertently.......................(ii) Other than above ..................................................(i) Less than 1/3 of lever travel remains when the

brake is fully applied..............................................


P

PG

G

G

With conditions

3.3 Pipes, hoses and connectors

BCU

BCI1

BCL1

BCN1

BCY1

(a) A brake pipe is not supported over a span of >700mmfor 6 to 10mm pipe, or > 1000mm for 10 to 18mmpipe

(b) A brake pipe or shielded brake hose is fitted within


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BCW1

BCW1

BCW1

BCJ1

(f) The cross sectional area of a brake pipe or hose isreduced, e.g. as a result of denting or kinking

(g) A brake hose bulges under pressure

(h) A brake hose is cracked or chafed

(i) A brake pipe, hose or connector is otherwisedamaged, incl. cracked pipes or connectors; andtwisted or stretched brake hoses

(iii) The pipe or hose is blocked or almost blocked,e.g. any part of a pipe is flat or almost flat, or ahose is kinked ........................................................

(iv) The cross-sectional area is significantly reduced(v) Other than above ........................................................................................................................................(i) Cracking or chafing extends all the way through

the hoses outer layer, i.e. subsequent layers of

the hose are visible ................................................(ii) Less than above....................................................(iii) More than above ...................................................(i) A pipe or connector is cracked, or failure is

imminent................................................................(ii) A pipe or hose is twisted or stretched but failure

is not imminent ......................................................

PGY

G

G

Y

P

P

G

3.4 Linkages and mechanisms

BEY1

BEY1

BSA[QUAL]

BAA1

(a) Any part of a brake mechanism is not securely fitted orattached

(b) A locking device is not fitted, loose, or not of anapproved type

(c) Any part of a brake mechanism is in contact with anypart of the vehicle in a way that could cause damageor wear such as chafing

(d) A slack adjuster does not form an angle of close to 90when the brakes (in good adjustment) are applied withfull treadle pressure

......................................................................................(i) The locking device is missing or detached ...........(ii) The locking device is loose or insecure ................

......................................................................................

(i) If performance in 3.1(h) not met............................(ii) If performance in 3.1(h) met..................................

P

GG

G

PY


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BRY1

BRI1

BRJ1

BCY1

BAJ1

BUU

BUU

(e) A cable is damaged, e.g. knotted, corroded, chafed orhas broken strands

(f) A cable is joined in an unsuitable way, or is fitted withan auxiliary tensioner

(g) A rod is damaged, e.g. bent, corroded or chafed

(h) A pivot does not operate freely or has excessiveclearance

(i) A lever or slack adjuster is damaged, e.g. cracked,bent, corroded or worn

(j) A brake backing plate is loose

(k) A spider is loose

(i) The damage significantly weakens the cable orprevents its free operation.....................................

(ii) Other than above.......................................................

......................................................................................(i) The damage significantly weakens

1the rod or

prevents its free operation.....................................(ii) Other than above ..................................................

......................................................................................

(i) The damage significantly weakens1

the lever orslack adjuster, or prevents its free operation ........

(ii) Other than above ..................................................(i) The backing plate is in contact with other brake

components, or brake efficiency is reduced........(ii) The spider is in contact with other brake

components, and/or brake efficiency is reduced.(iii) Other than above ........................................................................................................................................

GY

G

GY

Y

GY

G

PY

Y

With conditions

With conditions

1The cross-sectional area isreduced by >25%.


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3.5 Air compressors and vacuum pumps

AAY

AVU1

ARI

ARI

(a) An air compressor or vacuum pump is missing, doesnot operate or does not operate correctly, or hasexternal damage or leaks

1

(b) An air compressor or vacuum pump has loosemounting bolts, cracked or broken mounting brackets,braces or adapters, or is excessively corroded

2

(c) A compressor or vacuum pump drive belt is cracked,frayed or slipping

1

(d) A drive pulley is cracked, broken or loose3

......................................................................................

......................................................................................(i) The pressure build-up time is seriously affected

or failure is imminent ..............................................(ii) Other than above .........................................................................................................................................

P

G

PY

G

1Some air brake components havea limited amount of leakage whichis acceptable. A small amount oflubricating oil leakage is alsoacceptable as long as theoperation of components is notadversely affected.

2Corrosion must not weaken thestructure or mounting of brakecomponents, or adversely affecttheir operation.

3Cracked through to reinforcingplies, extensively frayed or missingdrive sections.


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3.6 Actuators, valves and reservoirs

BIY1

BII

BWY1

BWE1

BWL1

ATY1

ATG1

AVL

(a) An adjustment indicator rod is missing or seized

(b) An adjustment indicator rod indicates excessivetravel

1

(c) A brake chamber (including chamber clamps) orcamshaft support bracket is loose, bent, cracked orcorroded

(d) The stroke of the brake chamber exceeds themanufacturers limit

(e) A calliper or wheel cylinder leaks, or there is anaudible air leak from a brake chamber

(f) A reservoir, master cylinder or servo unit leaks, or is

loose, cracked, corroded, broken, otherwise damagedor worn

(g) An air reservoir contains an excessive amount of oil orwater (air brake reserve is effected to where therequired number of brake applications do not meet therequirements)

(h) A load sensing valve leaks, is out of adjustment or not

operational, e.g. missing, seized, by-passed ordisconnected

............................................................................................................................................................................

(i) Detachment or failure is imminent on a singlesteer front axle ......................................................

(ii) Other than above ..................................................(i) If performance in 3.1(h) not met...........................(ii) If performance in 3.1(h) met..................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

Y

G

PY

PY

G

G

G

G

Brake actuators include: air brake actuators; wheel cylinders; disc brake callipers; and slack adjusters.


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3.7 Drums, discs, shoes and pads

BDJ

BDU

BDGBDNBDW

BLF

BEY

BEUBEJ

(a) A brake drum or disc is not fitted or has pieces missing(b) A brake drum or disc is not securely fitted or has

cracks1

(c) A drum or disc is excessively corroded2, excessively

worn3, warped or contaminated by brake fluid, oil orgrease

(d) A brake lining or pad is missing, not securely fitted,cracked, or excessively worn

4

(e) A shoe spring, anchor pins, cam roller, clevis pin or

retainer is missing or damaged

......................................................................................(i) The drum or disc is fractured through, a crack

opens when the brake is applied, or failure isimminent................................................................

(ii) Other than above ..................................................(i) Failure is imminent................................................(ii) Other than above ..................................................

(i) The brake lining or pad is missing, detached orworn to the metal....................................................

(ii) The brake lining or pad is worn below themanufacturers limit ................................................

(i) Brake efficiency is reduced:

On a single steer front axle .................................... On an axle other than a single steer front axle ......(ii) Other than above ..................................................

P

PG

PY

P

Y

PGY

1Does not apply to short heat cracksinside the drum.

2Corrosion must not weaken thestructure or mounting of brakecomponents, or adversely affecttheir operation.

3 Drum or disc wear must not exceedmanufacturers specifications.

4Brake lining wear indicators arenormally milled into the lining.


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3.8 Compressed air system capacity

AAY

ARY

AAI

Reservoir capacity(f) The required number of brake applications cannot be

performed

Compressor capacity(g) Air pressure build up is slow

The low pressure warning is activated before1:

(i) 3 full service brake applications2

with fullrelease for combinations having anemergency or breakaway valve on thetrailer and a tractor protection valve on thetowing vehicle .................................................

(ii) 5 full service brake applications with fullrelease for other vehicles ....................................

The compressor does not raise system pressure tothe point where the compressor unloads before thefollowing maximum time limits

3:

GSVs(iii) 3 minutes: starting from the pressure at which

low pressure warning ceases to operate, or in

vehicles so equipped, the emergency brakeoperates...............................................................

(iv) 1.5 minutes: starting from the pressure thesystem is at after carrying out either 3 or 5 fullservice brake applications, as required above ....

PSVs(v) 1.5 minutes: starting from the pressure the

system is at after carrying out 5 full service

brake applications as required in the reservoircapacity requirements above...............................

G

G

G

G

G

1The test is to be conducted withthe brake system at its maximumspecified operating pressure, theengine stopped and the parkbrake released.

2A full service brake application ismade when all the brakes havebeen fully applied to stop thevehicle combination in therequired distance.

3The test is to be conducted withthe engine operating at itsmaximum governed speed. If theengine is not governed, theinspector must determine theengines safe maximum operatingspeed.


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3.9 System protection and instrumentation

ADC

ATC

AWO

(a) An auxiliary air operated device is fitted to the brakesystem without the approval of the manufacturer or theDirector, or an approved system is found to bedamaged or modified, for example:

the operation of an auxiliary device lowers the pressureof the brake system below two thirds of its maximumoperating pressure; or

an auxiliary device which requires a significant1

amountof compressed air uses the same source ofcompressed air as the brake system and shares airfrom the brake systems reservoir, i.e. does not have itsseparate reservoir

(b) A receiver that is used to supply the brake systemdoes not have a gauge fitted

2, the gauge is not

operational, inaccurate, not illuminated, or is notreadily visible from the drivers seat

(c) An audible warning device is missing, does notoperate, operates at a pressure lower than the

manufacturers minimum recommended pressure3 orcannot be easily heard from the drivers seat

......................................................................................

......................................................................................

(i) If gauges operational.............................................(ii) If gauges not operational.......................................

G

G

YG

1Significant in relation to the amount

of compressed air required for theoperation of the brake system.Significant amounts are typicallyrequired by air spring suspensionsystems, central tyre inflationsystems or pneumatically-operatedpassenger doors.

2An alternative device to a gauge

may be used provided that theDirector approves the device.

3If the manufacturers minimum

recommended operating pressure isnot available, it is deemed to be50% of the maximum operatingpressure.


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3.10 Spring brakes

BVY1 (a) A spring brake air circuit does not have a non-compounding valve fitted

1

(b) A required spring brake emergency release control isnot fitted, cannot be operated from the drivers seat

2or

sources its air supply from a reservoir that is notprotected

3

(c) A spring brake control used for operating the parkingbrakes is not protected from inadvertent release

......................................................................................

......................................................................................

......................................................................................

Y

Y

Y

1Non-compounding valves are notrequired on some vehicle models. Insuch cases:

Written confirmation from themanufacturer or manufacturersrepresentative is required; and

The brake system must beunmodified.

2Trailer spring brakes do not have tobe capable of being released fromthe towing vehicles cab provided thatthey can be released using air from atrailer-mounted emergency reservoirand the emergency release valve islocated in a position that:

Is protected from the chassis rail orfitted with a guard; and

Is inconspicuous and can beaccessed without danger to theoperator

3Air for the release of spring brakesafter an automatic application dueto loss of service brake pressuremust besourced in:

A PSV, from a protected reservoir*

A GSV or SPV from a protectedreservoir* or the spare wheel

* The reservoir must be protected fromthe service brake system by a one-wayvalve. Note: Split service brakesystems do not have separate protectedrelease systems.


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3.11 Vehicle combinations 39 to 44 t

BOC1

BOC1

(a) A vehicle used in a combination with a GCM between39,000 kg and 44,000 kg is not certified for compliancewith either the IHVBS or the NZHVBC

1

(b) A vehicle is modified from its condition when certifiedfor compliance with the IHVBS or the NZHVBC so thatits brake performance is affected by the modificationand it is not certified

(c) A vehicle certified only to the IHVBS is used in acombination between 39,000 kg and 44,000 kg GCMbut that combination is not listed on the towingvehicles CoL

(d) The spring media within an axle set are not all of thesame type

(e) An axle set is clearly not load sharing, e.g. a balancebeam between two dual tyred axles is not of equallength

(f) A vehicle or modification certified to the IHVBS orNZHVBC does not have a required statement ofcompliance or certification document, certificationplate, CoL entry or modification certificate, or the

statement or document, plate, entry, or certificate isinvalid illegible, incomplete, or incorrect

Combination down rated to 39000kg

..............................................................................

..............................................................................

..............................................................................

..............................................................................

..............................................................................

..............................................................................

G

G

G

Y

Y

Y

With conditions (ie Reduced to 39tonne)

1IHVBS: Interim Heavy VehicleBraking SpecificationNZHVBC: NZ Heavy Vehicle BrakeCode


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BCY

BCY

BLY

BLC

ATY

BCC

Additional to IHVBS vehicles(g) A brake connection between vehicles is fitted that is

not a two line type

(h) A brake connection is not colour coded2

and can beincorrectly connected

Additional to NZHVBC vehicles(i) A brake lining is fitted that does not comply with the

NZHVBC3

(j) Brake linings are replaced clearly on one side of anaxle set only

(k) A brake reservoir condensate drain valve is missing,does not operate manually or is not located at thelowest point of the reservoir

4

(l) A brake coupling is not one piece5, incorrectly coloured

coded6

or not mounted close to the vehicles centre

line or has other coupling connection devices thatcould be used inadvertently

......................................................................................

......................................................................................

......................................................................................

(i) Brake performance imbalance..............................(ii) Not imbalanced .....................................................

......................................................................................

(i) Not in one piece ....................................................(ii) Other than above ..................................................

G

G

Y

GY

Y

GY

2Control line: yellow, green or blueSupply line: red

3If there is evidence that a

component does not meet therequirements of the NZHVBC, thevehicle inspector may require thebrake maintenance records to beproduced

4If an automatic condensate valve isfitted:

The valve must be capable of

manual operation or The reservoir must also have a

manual drain valve fitted

5Duomatic, Trimatic or equivalent

6Colour coded within 150mm of thecoupling and mounted in thefollowing manner: Left side of coupling: control line,

coloured in blue or black; and Right side of coupling: supply

line, coloured in red or yellow.


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ULJ

UBY

UBY

UBW

APPL

UXY

(f) The main leaf(s) or more than 1/4 of the leaves in one

leaf spring assembly are missing, damaged or cracked(g) An air spring is deflated, leaks

4, or the strength of a

bellow is adversely affected through damage ordeterioration

(h) There is no rebound arrestor

(i) A rubber spring shows signs of bonding failure

between the rubber and metal elements, or issignificantly damaged or deteriorated so that theoperation of the spring is adversely affected

(j) The alloy mount hose is cracked, corroded ordamaged

......................................................................................

............................................................................................................................................................................

(i) Total failure.............................................................(ii) Signs of failure .......................................................

......................................................................................

P

P

Y

PG

G

4Including pipe work and valving.

With conditions

4.3 PSV suspension

UGS

UGY

(a) A suspension safeguard or its mounting is damaged,e.g. insecure, bent, cracked, excessively corroded orotherwise weakened

(b) A suspension safeguard or its mounting detachmentis imminent

.....................................................................................

.....................................................................................

Y

G


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4.4 PSV drive shaft retention

MSY

MSY

(a) A drive shaft surround does not surround the driveshaft or does not prevent the drive shaft from strikingthe ground, chassis or floor

(b) Detachment of drive-shaft retention device

....................................................................................Detachment is imminent.............................................

Y

G


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WTJ

WTJ

WTC

WTY

(j) A tyre is damaged

(k) A tyre is repaired using a string repair from the outside

(l) A re-grooved tyre is not intended to be re-grooved, oris fitted to a vehicle that is used at speeds above 50km/h but not covered by an exemption

(m) A rim is damaged

(i) A lump or bulge is present, a cut reaches the

body cords or exceeds 25mm in length, or thereis other significant damage; and: failure of the tyre is imminent or the vehicle

cannot be operated safely ................................. the operation of the vehicle is adversely

affected but failure is not imminent....................(ii) Other than above ........................................................................................................................................

......................................................................................(i) A rim is cracked or distorted, or there is other

significant damage; and: failure of the rim is imminent or the vehicle

cannot be operated safely .................................

the operation of the vehicle is adverselyaffected but failure is not imminent....................


P

GY

Y

Y

P

G

Y


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4.7 Equipment locking devices

EFYEFWEFUEFS

EFYEFWEFU

EFS

EBYEBWEBUEBS

(a) A sliding axle set or sliding chassis, or an outriggerfitted to a vehicle does not have an effective lockingdevice by visual inspection.

(b) Class NB and NC vehicles fitted with swivel cranewhen the lock device is not readily seen doesn nothave an audible or visual alarm, or it is not locking

when the landing leg is not in a fully retractedposition.

(c) A sliding axle set does not have end-stops.

(i) There is no locking device fitted .........................(ii) There is significant risk to other road users........

(i) The alarm is not fitted .........................................(ii) The alarm does not operate ...............................

(i) Never fitted .........................................................(ii) Fitted but damaged.............................................

G

P

G

G

GG

(See section 3.9 (5) for energisedlocking system initiation)


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5. Occupant safety

5.1 Vehicle structural strength and condition

CRSCCSELSECS

CDUCDU

(a) Any of the following components are damaged (e.g.corroded

1, deformed or cracked

2) or not securely fitted:

chassis rails;

cross members;

deck attachments; or

cab and body attachments

(b) Any part of a load containment structure is damaged ornot securely fitted

There is a significant risk of a component failing orthe vehicle cannot be operated safely:

The vehicle is loaded......................................... The vehicle is unloaded.....................................

There is a significant risk of the structure failing: The vehicle is loaded......................................... The vehicle is unloaded.....................................

PG

PG

1Corrosion: Corrosion is most likely to occur

in areas where moisture isretained. If rust heave betweena chassis member and a fixtureexceeds twice the thickness ofthe chassis member, or amaximum of 6 mm, the chassisshould be inspected by aspecialist certifier.

Particular attention should bepaid to any vehicle used to carrystock, fertiliser or corrosive cargo.

Rust stains can indicate thefretting or movement betweentwo components. This can becaused by loose fasteners or bycracking.

2Chassis cracking is most likely tooccur in the following areas: abrupt changes in area; adjacent to welds; body mounting points; adjacent to loose fasteners; and notches.


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Code I ti it d d i ti f d f t S it f d f t (if li bl ) d d f t t N t


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IGO

IGY/IGC

IGY

ILY

ILY

(e) A power-operated retractable step can be operated

with a person standing on the step

(f) A vehicle with a power-operated retractable step canbe operated with the step extended

(g) A power-operated retractable step protrudes >10mmbeyond the body line of the vehicle when retracted

(h) A doorway, step, ramp or aisle is not fitted with an

interior lamp, or the interior lamp fitted is notoperational or does not provide adequate illumination3

(i) An interior lamp interferes with the drivers vision whenthe vehicles doors are closed

......................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

G

P

Y

Y

Y

Doesnt apply if door in direct view ofdrivers field of vision

3Refer to the HMVSIG forexemptions

5.5 Seats, general

ISY

ISU

(a) A vehicle is not fitted with a seat for the driver

(b) A seat is not securely fitted to the vehicle

The vehicle cannot be operated safely.........................(i) Detachment is imminent or there is a significant

risk of the seat detaching under load, e.g. in theevent of an emergency stop or accident:

The seat is a drivers seat ...................................... The seat is a seat other than a drivers seat..........(ii) Detachment is not imminent but the seat

structure or mounting points are weakenedthrough damage or deterioration............................

P

PG

G

Code Inspection item and description of defect Severity of defect (if applicable) and defect category Notes


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5.6 PSV seating

ISY

ISY

IDY

IDY

IDY

(a) The fitting of a seat obstructs the view of the driver, orrestricts access to an emergency exit or the movementof passengers

(b) A seat or the spacing of seats does not comply withdimensional requirements

1

(c) A required panel, guard rail or arm rest is not fitted1

(d) A folding seat for crew members does not comply withapplicable requirements

(e) A folding seat for passengers in a heavy PSV does not

comply with applicable requirements

......................................................................................

............................................................................................................................................................................

(i) The seat does not fold away automatically when

unoccupied or cannot be secured in the fold-away position ........................................................

(ii) A sign identifying the seat as a crew seat andadvising that the seat must be secured in thefold-away position when not in use is not fitted ....

(i) The seat is fitted in the stairwell in front of the

front axle, there is no unobstructed doorway infront of the front axle, or the seat cannot besecured when in use or when folded away...........

(ii) Instructions relating to the operation of the seatare not fitted ..........................................................

P

G

Y

Y

Y

G

Y

1Refer to the HMVSIG for details.



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5.7 PSV passenger compartment

IDY

ELY

IDI

IEI

IEI

IEI

IEY

IEF

CDY

CDY

IWY

(a) There are fittings or protrusions in the passengercompartment that could cause injury to occupants

(b) The body of a chassis type vehicle is not securelyfitted to the chassis

(c) Required padding is not fitted1

(d) A required aisle is not available

(e) An aisle is obstructed by a permanent fitting

(f) An aisle does not comply with dimensionalrequirements

1

(g) Aisle steps, ramps, landings, or handrails faulty

(h) Holds or grips are not fitted

Additional to open-bodied vehicles(i) A side wall of an open-bodied vehicle does not extend

at least 450mm above the uncompressed seatcushion

2

(j) A vehicle does not have a permanent frame to provideoccupant protection in a rollover

(k) A heavy PSV with an upper deck does not have a frontscreen that extends at least 1m above theuncompressed seat cushion and 1.95m above the floorlevel

3

......................................................................................

............................................................................................................................................................................

............................................................................................................................................................................

............................................................................................................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

G

P

Y

G

G

G

G

Y

P

P

G

1Refer to the HMVSIG for paddingrequirements.

2 Applies to vehicles that entered

service as PSVS on or after01/01/01.

3Applies to vehicles that enteredservice as PSVs on or after01/07/01.



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5.8 PSV drivers seat and vision

ISY

ISY

IXY

ISY

IWY

IWY

(a) A drivers seat cannot be accessed easily

(b) A drivers seat cannot be adjusted

(c) Driving controls are not protected from accidentaloperation

(d) A seat is fitted to the left of the drivers seat and there

is encroachment into the drivers operating space1

(e) The drivers field of view to the front, left or right isobstructed

(f) The drivers field of view2

of the interior or the exteriorvicinity of the passenger doors is obstructed

............................................................................................................................................................................

......................................................................................

......................................................................................

(i) The obstruction significantly impairs the driversfield of view and does not allow for the safeoperation of the vehicle.........................................

(ii) The obstruction reduces the drivers field of viewand makes the safe operation of the vehicledifficult (e.g. the driver has to lean forward inorder to gain a view to the left or right) .................

......................................................................................

Y

Y

Y

G

P

G

G

Drivers view is obstructed by somemodification

1

Refer to the HMVSIG for details

2The view may be direct or indirect,i.e. mirrors and CCTV systemsmay be used.



50/65

p p y ( pp ) g y



5.9 PSV emergency exits

IEY

IEY

IEO

IEO

IEY

IEY

IEO/IEY

IEY

(a) A vehicle does not have the required number ofemergency exits

(b) An emergency exit is not readily accessible

(c) An emergency exit is difficult to operate or its operationrequires excessive force

(d) A dedicated emergency exit does not comply withdimensional requirements

1

(e) A dedicated emergency exit cannot be operated fromthe inside or the outside of the vehicle

(f) A dedicated emergency exit opens inwards or, ifhinged and fitted on either side of the vehicle, ishinged on its rear edge

(g) A dedicated emergency exit equipped with locks doesnot have a device fitted warning the driver that the exitis locked when the vehicles engine is running

Additional to dedicated emergency exit windows(h) An emergency exit window intended to be broken in an

emergency is not made from readily breakable

toughened glass

(i) For an emergency exit window intended to be brokenin an emergency, a requirement relating to a special-purpose hammer is not met

............................................................................................................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

(i) No special-purpose hammer is fitted near to thewindows..................................................................

(ii) Some of special purpose hammers are missing...(iii) An alarm warning the driver of any tampering

with the hammer is not fitted or not operational ..(iv) Instructions relating to the operation of the

hammer are not fitted ..........................................

G

G

G

G

P

G

G

G

GY

Y

G

Green if the person can make iteasier or rectify it immediately.

1Refer to the HMVSIG foremergency exit requirements


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5.11 PSV passenger signals

IJO/IJY

(a) A vehicle in which communication betweenpassengers and the driver is restricted does not havea system for communication in emergencies fitted, ora fitted system is not operational .....................................................................................

Y

5.12 PSV towing and tow bars

TMY

TMC

TMY/TMC

VCY

(a) Tow bar is in poor condition loose

(b) A tow bar is not certified for compliance with NZS5467

1

(c) A PSV is towing a trailer

(d) Reference is not made on COL and yet is certified

......................................................................................(i) Towing ...................................................................(ii) Not towing ..............................................................

......................................................................................

......................................................................................

G

PG

P

Y

1Applies to vehicles that enteredservice on or after 1/9/99 orvehicles that had the tow bar fittedon or after 1/9/99.

5.13 PSV load security

IRY (e) A vehicle carrying large or heavy items of luggage orfreight is not fitted with appropriate containmentfacilities such as under floor lockers or cargo barriers

(i) There is a significant risk of occupants beinginjured by loose items of luggage or freight , e.g.in the event of an emergency stop or an accident .

(ii) Other than above ...................................................

G

Y



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5.14 PSV roof racks

IRC

IRU

IRC

VCD

(a) A roof rack is not rated and certified by an LTSAapproved certifier

(b) A roof rack is insecure

(c) A roof rack is not fitted with a compliance plate or acompliance plate that does not contain the requiredinformation

1

(d) Reference to roof rack not on CoL

(i) Loaded ...................................................................(ii) Unloaded................................................................(i) The roof rack is not securely fitted and

detachment is imminent .........................................(ii) The roof rack is not securely fitted but unlikely to

detach if unloaded..................................................

(iii) Other than above ...................................................

......................................................................................(i) Loaded ...................................................................(ii) Unloaded................................................................

PG

P

G

Y

G

YY

1Refer to the HMVSIG for roof rackcompliance plate requirements.

5.15 PSV ventilation

IAF

IAY

IYY

IAI

IAC

(a) A ventilation system is not fitted for passengers1

(b) An independent ventilation system is not available forthe driver

1

(c) Window or roof openings cannot easily be opened andclosed

(d) A forced ventilation system is not operational, noteffective or does not comply with applicablerequirements

2

(e) A forced ventilation system, incl. Any heating or airconditioning system, is not designed, constructed andmaintained so that the risk of injury to occupants isminimised

......................................................................................

......................................................................................

......................................................................................

......................................................................................

......................................................................................

Y

Y

Y

Y

Y

1Ventilation may be by way ofwindow or roof openings, or byforced ventilation (fans)

2Refer to the HMVSIG for details



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5.16 PSV demisters

IAY (a) A vehicle is not fitted with a demisting system for thewindscreen and the front side windows, or system isnot effective ......................................................................................

G



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6. External safety

6.1 Mudguards

WGY

WGY

WGU

(a) A mudguard or mud flap is not fitted over appropriateroad wheel

1

(b) A mudguard or mud flap is not effective or does notcomply with applicable requirements

2

(c) A mudguard or mud flap is not securely fitted

......................................................................................

......................................................................................(i) Detachment is imminent........................................

(ii) If driver rectifies it on the spot ...............................

G

G

P

Y

1Refer to the HMVSIG forexemptions.

2Refer to the HMVSIG for mudguardand mud flap requirements.

6.2 Exhaust system

MEY

MEY

MEU

MEY

(a) A vehicle with an internal combustion engine is notfitted with an exhaust system

1

(b) An exhaust system that is not effective, because it hasbeen properly maintained, or has been damaged

(c) An exhaust system is not securely fitted

(d) PSV exhaust system exists on left hand side of thevehicle

......................................................................................(i) The system leaks or creates excessive noise.......


......................................................................................

G

G

PY

G

1The exhaust system includesmanifolds, silencers, pipes,gaskets, mounting hardware andheat shields, fitted to protect firerisk.



56/65



6.3 External projections

EFY/EFU

EFY

EBY/EBU

EBR

(a) An external ornamental fitting protrudes from thevehicle in a way that poses a significant safety risk toother road users

(b) An external functional fitting1

is maintained in a waythat possess a risk of injury to other road users

(c) A damaged or deteriorated part of the vehicle poses asignificant safety risk to other road users

(d) An external fitting, or a damaged or deteriorated part ofthe vehicle, adversely affects the drivers view orcontrol of the vehicle

......................................................................................

(i) Can not be rectified................................................(ii) Can be rectified or made safer...............................

......................................................................................

......................................................................................

P

PG

P

P

1Examples for functional fittings arebull bars, winches, tow balls andside racks for ladders.


57/65



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7.2 Bolster attachments

ELC

ELU

ELC/

ELY

ELC

ELC

(a) A logging bolster fitted on or after 27/11/98 is notcertified for compliance with the Bolster AttachmentCode of 27/11/98

1&2

(b) A bolster is not securely fitted to the vehicle, or abolster or bolster attachment is damaged

(c) A sliding bolster does not have an effective locking

mechanism

(d) An HVEL certifying engineers report is not availablefor a modification or successive repairs to a bolsterattachment

(e) A vehicle fitted with bolsters the attachments of whichrequire certification does not have a correspondingcertification label or document, or the certification labelor document is invalid, illegible, incomplete or incorrect

(i) Loaded ..................................................................(ii) Unloaded...............................................................

(i) The integrity of the bolster or bolster attachmentis significantly compromised

3and there is an

immediate risk of failure:

The vehicle is loaded......................................... The vehicle is unloaded.....................................

(ii) The integrity of the bolster or bolster attachmentmay be compromised but there is no immediaterisk of failure: The vehicle is loaded......................................... The vehicle is unloaded.....................................

(i) No locking mechanism...........................................

(ii) Locking mechanism fitted but not utilised ..............

......................................................................................

(i) If theres no belly chain .........................................(ii) If a belly chain can be fitted immediately..............

PG

PG

GY

G

G

G

G

Y

1Unless exempted by notice in theNew Zealand Gazette, subject tothe use of an additional 6t capacitybolster chain on each bolster.

2Logging bolsters fitted to newvehicles after 01/10/99 must becertified to the bolster attachment

code.3

For example, there is significantdamage such as cracks,deformation or corrosion, orexcessive wear.



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7.3 Drawbeams

TMC

TMU

TMC

TMC

(a) A drawbeam or towing connection is not certified asrequired

1or has expired

(b) A drawbeam is not securely fitted to the vehicle, atowing connection is not securely fitted to thedrawbeam, or a drawbeam or towing connection isdamaged or cracked

(c) An HVEL certifying engineers report is not availablefor a modification or successive repairs to a drawbeamor towing connection

(d) A drawbeam or towing connection does not have acorresponding certification label or document, or the

certification label or document is expired, invalid,illegible, incomplete or incorrect3

or is not recorded onthe CoL

......................................................................................(i) The integrity of the drawbeam or towing

connection is significantly compromised2

andthere is an immediate risk of failure:

In use......................................................................

Not in use ...............................................................

(ii) The integrity of the drawbeam or towingconnection may be compromised but there is noimmediate risk of failure ........................................

......................................................................................

(i) Unloaded...............................................................(ii) Loaded ................

comprehensive-inspection-guidelines-v1

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