540 CMR 4.00

4.05 Procedures for Inspection of Commercial Vehicles

(1) Prior to Beginning Inspection, a visual check of the vehicle shall be made to determine that ice and snow accumulation or the condition of the suspension system, will not impede or interfere with the proper aiming of headlamps. The inspector may refuse to inspect the vehicle if it is determined by the inspector that the vehicle is unsafe for operation on the dynamometer or for any aspect of the Safety or Safety and Emissions inspection.

(a) The Certificate of Registration shall be inspected and the information contained thereon, including license plate, vehicle description, and vehicle identification number, shall be verified by observation of the subject vehicle. The information contained on the Certificate of Registration shall also be matched with the vehicle information accessible to the workstation. The data appearing on the Registration Certificate, the accessible to the Workstation, the data appearing on the vehicle license plate, and the vehicle identification number and description must match in order for the inspection to proceed. No fee shall be assessed for an inspection which does not proceed due to a data match failure.

(b) A Vehicle Identification Number Correction Form must be given to the operator of any vehicle refused for inspection due to an incorrect vehicle identification or registration number.

(c) No certificate of registration need be produced for vehicle having a general registration issued in accordance with the provisions of M.G.L. c. 90, § 5. Either a photocopy of the original certificate of registration or the original certificate of registration may be produced for other motor vehicles.

(d) A licensed inspector may refuse to conduct an inspection if the motor vehicle's registration is determined to be invalid.

(2) Inspection of the Vehicle. All inspections must be performed in accordance with the applicable provisions of 540 CMR 4.00 and 310 CMR 60.02 by licensed inspectors in the approved inspection bay only.

(a) Inspectors must first collect the proper fee.

(b) License plate(s), shall be undamaged, securely mounted, clean and clearly visible. No bumper, trailer hitch or other accessory may interfere with a clear view of the license plates. The license plate must be mounted in the proper location on the rear of the vehicle if the vehicle has been issued one plate. Both license plates must be mounted in the proper location on the rear and front of the vehicle, if the vehicle has been issued two plates. Any decorative license plate or license plate replica not issued by the Registry of Motor Vehicles on which the word "Massachusetts" appears must be removed from the vehicle.

(d) General Registration Holders, every motor vehicle in possession of a general registration holder shall be checked for the proper display of the compliance decal issued pursuant to 540 CMR 18.03. The Vehicle Identification Number (V.I.N.) and Registration Number indicated on the decal shall correspond with said number of the vehicle inspected. This requirement does not apply to motor vehicles owned and registered by a dealer.

(e) Upon the completion of the inspection, the inspector will remove the old certificate of inspection from the windshield, trailer, semi-trailer, or converter dolly and affix the new Certificate of Inspection.

(3) Reflectors. Every commercial motor vehicle or trailer weighing, with its load, more than 12,000 pounds shall be equipped with a red reflector at the rear.

(4) Chock Blocks. Every bus having a seating capacity of more than seven passengers, every truck weighing, unloaded, more than 4,000 pounds and every tractor, trailer, semi-trailer or combination which is not equipped with positive spring loaded, air parking brakes, shall be equipped with one pair of adequate safety chock blocks.

(5) Splash Guards. Every motor vehicle or trailer, except passenger motor vehicles, shall be equipped with suitable guards which will effectively reduce the spray or splash, to the rear, of mud, water, or slush, caused by the rear wheels.

(6) Marker Light. Commercial motor vehicles and trailers, having a registered carrying capacity of three tons or over, shall have an amber light attached to the extreme left of the front of the vehicle, so attached and adjusted as to indicate the extreme left lateral extension of the vehicle or load.

(7) Horn. Sound horn to test for adequate signal. The horn must be securely fastened to the vehicle.

(8) Warning Devices. Every commercial motor vehicle or trailer that is required to have a backup warning device shall be checked for proper operation of said device. Every commercial motor vehicle equipped with a dump body shall be equipped with an adequate audible warning system to alert the operator when the dump body is in an upright and elevated position.

(9) Bumpers. The existence of broken or bent bumpers, fenders, exterior sheet metal or moldings having sharp edges or abnormal protrusions extending beyond normal vehicle extremities so as to constitute a danger to pedestrians and other motor vehicle traffic shall be reason for rejection. If bumper face plates are removed, bumper brackets must also be removed. The vehicle hood, door(s), luggage compartment lid, and battery or engine compartment doors or lids, if so equipped, must be capable of being firmly latched.

(10) Fenders. Front and rear fenders must be in place. Every commercial motor vehicle which is equipped with tires which extend beyond the fenders or body of such vehicle shall be equipped with flaps or suitable guards to reduce such spray or splash to the rear and side.

(11) Seat Belts. Shall be inspected to assure that all are maintained in good order. The Requirements of Title 49 Code of Federal Regulations, Part 393.93 shall apply.

(12) Procedures for Inspecting Certain Commercial Motor Vehicles and Trailers Pursuant to Federal Regulation. 49 CFR Parts 390 through 397 of Title 49, including Appendix G to Sub-Chapter B, as appearing or as may be revised in the Code of Federal Regulations, as related to the inspection of Commercial Motor Vehicles or any activity related thereto, are hereby adopted as the Regulations of the Registry of Motor Vehicles. Said regulations are applicable to trucks with a gross vehicle weight rating of over 10,000 pounds, buses transporting more than 15 passengers including the driver or any motor vehicle transporting hazardous materials in a quantity requiring placarding in accordance with the Hazardous Material Regulations of the United States Department of Transportation, parts 171 through 180 of Title 49, Code of Federal Regulations. In the event of any conflict between these regulations and any other regulations or law of the Commonwealth of Massachusetts, the stricter more stringent standard shall apply. A Certificate of Rejection shall be issued to any vehicle or trailer submitted for inspection if any of the following conditions exist:

(a) Air Brake Systems.

1. Leakage Test. Start the vehicle engine and run at fast idle until air pressure on gauge reaches cut-off point. Cut-off must occur at 90 pounds per square inch or more, or manufacturer specifications. Stop engine and observe pressure gauge. With service brakes in released position, if drop in pressure exceeds 2 PSI in one minute for a single vehicle or 3 PSI for a combination vehicle or if audible leakage is evident, the vehicle will be rejected. Start engine and allow system to reach maximum pressure. Stop engine and apply service brakes, at which time a pressure drop of 5 PSI to 15 PSI will occur and system will be stabilized. With brakes in applied position, if drop in pressure exceeds 3 PSI in one minute for a single vehicle, or 4 PSI per minute for a combination vehicle, or of audible leakage is evident, the vehicle will be rejected.

2. Low Pressure Warning Device Test. Apply service brakes repeatedly until the audible or visual low pressure indicator comes on. Reject vehicle if indicator comes on above 70 PSI or below 50 PSI or if the indicator is inoperable. A gauge indicating pressure is not deemed to be an adequate low pressure indicator.                                                                                                                                
3. Condition of Air Brake Components. During the inspection of the vehicle, the conditions of visible air brake components should be checked. The vehicle shall be rejected if tubing or hoses are cracked, chafed, or restricted or are insecurely fastened or improperly retained.

(b) Brake System.

1. Service Brakes.

a. All brake systems are to be inspected in accordance with the manufacturer(s) recommended procedures. Absence of braking action of any axle required to have brakes upon application of the service brakes (such as missing brakes or brake shoe(s) failing to move upon application of a wedge, S-cam, cam, or disc brake).

b. Missing or broken mechanical components including shoes, lining, pads, springs, anchor pins, spiders, cam rollers, push rods, and air chamber mounting bolts.

c. Loose brake components including air chamber spiders, and cam shaft support brackets.

d. Audible air leak at brake chamber (example-ruptured diaphragm, loose chamber clamp, etc.).

e. Re-adjustment limits. The maximum stroke at which brakes should be readjusted is given below. Any brake 1/4" or more past the re-adjustment limit or any two brakes at the readjustment limit on less than 1/4" beyond the re-adjustment limit shall be cause for rejection. Stroke shall be measured with the engine off and reservoir pressure of 80 to 90 PSI with brakes fully applied.

BOLT TYPE BRAKE CHAMBER DATA

Type	Effective area (sq. in.)	Outside dia. (in.)	Maximum stroke at which brakes should be readjusted
A	12	6 15/16	1 3/8
B	24	9 3/16	1 3/4
C	16	8 1/16	1 3/4
D	6	5 1/4	1 1/4
E	9	6 3/16	1 3/8
F	36	11	2 1/4
G	30	9 7/8	2

ROTOCHAMBER DATA

Type	Effective area (sq. in.)	Outside dia. (in.)	Maximum stroke at which brakes should be readjusted
9	9	4 9/32	1 1/2
12	12	4 13/16	1 1/2
16	16	5 13/32	2
20	20	5 13/16	2
24	24	6 13/32	2
30	30	7 1/16	2 1/4
36	36	7 5/8	2 3/4

CLAMP TYPE BRAKE CHAMBER DATA

Type	Effective area (sq. in.)	Outside dia. (in.)	Maximum stroke at which brakes should be readjusted
6	6	4 1/2	1 1/4
9	9	5 1/4	1 3/8
12	12	5 11/16	1 3/8
16	16	6 3/8	1 3/4
20	20	6 24/32	1 3/4
24	24	7 7/32	1 3/4
30	30	8 3/32	2

^1. Note: (2" for long stroke design).

Wedge Brake Data. Movement of the scribe mark on the lining shall not exceed 1/16 inch.

f. Brake linings or pads.

i. Lining or pad is not firmly attached to the shoe;

ii. Saturated with oil, grease, or brake fluid; or

iii. Non-steering axles: Lining with 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.

iv. Steering axles: Lining with a thickness less than 3/16 inch at the shoe center for drum brakes, less than 1/8 inch for air disc brakes and 1/16 inch or less for hydraulic disc and electric brakes.

g. Missing brake on any axle required to have brakes.

h. Mismatch across any power unit steering axle of:

i. Air chamber sizes.

ii. Slack adjuster length.

2. Parking Brake System. No brakes on the vehicle or combination are applied upon actuation of the parking brake control, including driveline hand controlled parking brakes.

3. Brake Drums or Rotors.

a. With any external crack or cracks that open upon brake application (do not confuse short hairline heat check cracks with flexural cracks).

b. Any portion of the drum or rotor missing or in danger of falling away.

4. Brake Hose.

a. Hose with any damage extending through the outer 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. Any audible leaks.

d. 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.

e. Air hose cracked, broken or crimped.

5. Brake Tubing.

a. Any audible leak.

b. Tubing cracked, damaged by heat, broken or crimped.

6. Low Pressure Warning Device missing, inoperative, or does not operate at 55 PSI and below, or 1/2 the governor cut-out pressure, whichever is less.

7. Tractor Protection Valve. Inoperable or missing tractor protection valve(s) on power unit.

8. Air Compressor.

a. Compressor drive belts in condition of impending or probable failure.

b. Loose compressor mounting bolts.

c. Cracked, broken or loose pulley.

d. Cracked or broken mounting brackets, braces or adapters.

9. Electric Brakes.

1. Absence of braking action on any wheel required to have brakes.

2. Missing or inoperable breakaway braking device.

10. Hydraulic Brakes. (Including Power Assist Over Hydraulic and Engine Drive Hydraulic Booster).

a. Master cylinder less than 1/4 full.

b. No pedal reserve with engine running except by pumping pedal.

c. Power assist unit fails to operate.

d. Seeping or swelling brake hose(s) under application of pressure.

e. Missing or inoperative check valve.

f. Has any visually observed leaking hydraulic fluid in the brake system.

g. Has hydraulic hose(s) abraded (chafed) through outer cover to fabric layer.

h. Fluid lines or connections leaking, restricted, crimped, cracked or broken.

i. Brake failure or low fluid warning light on and/or inoperative.

11. Vacuum Systems. Any vacuum system which:

a. Has insufficient vacuum reserve to permit one full brake application after engine is shut off.

b. Has vacuum hose(s) or line(s) restricted, abraded (chafed) through outer cover to cord ply, crimped, cracked, broken or has collapse of vacuum hose(s) when vacuum is applied.

c. Lacks an operative low-vacuum warning device as required.

Procedures for Inspection of Commercial Vehicles (continued)