Subsection 222-1-200-05 - TRANSMISSION AND BRAKES1. TRANSMISSION A. Test: If the vehicle is equipped with an automatic transmission, test the vehicle's transmission forward and reverse gears as well as the park position in automatic transmissions to ensure proper working order.B. Reject vehicle if the forward or reverse gears are inoperative.C. Reject vehicle if the park position is inoperative.D. Reject vehicle if the gear selection indicator does not properly identify the current gear position.2. BRAKES - ANTI-LOCKING SYSTEMS (ABS)A. Reject vehicle if the warning light fails to illuminate during the cycle or self-check, or a self-diagnostic error is indicated.B. Reject vehicle if the ABS braking system is disconnected or disabled.3. GENERAL FOR ALL BRAKE SYSTEMS A. Reject vehicle if there is an absence of braking action on any axle required to have brakes (such as missing brakes; brake shoes failing to move upon application of a wedge, S-cam, or disc brake).B. Reject vehicle if there are missing, loose or broken mechanical components including but not limited to: shoes, linings, pads, springs, anchor pins, spiders, cam rollers, clevis pins and clevises, push-rods, air chamber mounting bolts, or worn or frozen pins in slack adjuster. No bolts allowed in slack adjuster in place of clevis pins.C. Reject vehicle if there are loose brake components including; air chambers, spiders, cam shaft support brackets, or S cam bushings with more play than the manufacturers specifications allow.D. Reject vehicle if there are any audible air leaks at the brake chamber, air lines, tanks, valves, or connections.E. Reject vehicle if any brake is past the readjustment limit. Stroke shall be measured with engine off and reservoir pressure of 90 to 100 p.s.i.. with the brakes fully applied. The maximum strokes at which brakes should be readjusted are given below.F. Reject vehicle if there is a missing brake on any axle required to have brakes. Ref. CFR 49 393.48.G. Reject vehicle if there is a mismatch across any axle of air chamber size or slack adjuster length. CLAMP-TYPE BRAKE CHAMBER DATA (Dimensions in inches)
Type | Outside Diameter | Rated Stroke | Maximum Stroke at Which I Brakes Must Be Adjusted |
|
6 | 4 1/2 | 1.75 | 1 1/4 |
9 | 5 1/4 | 1.75 | 1 3/8 |
12 | 5 11/16 | 1.75 | 1 3/8 |
16 | 6 3/8 | 2.25 | 1 3/4 |
20 | 6 25/32 | 2.25 | 1 3/4 |
24 | 7 7/32 | 2.25 | 1 3/4 |
30 | 8 3/32 | 2.50 | 2 |
36 | 9 | 3.00 | 2 1/4 |
"LONG STROKE" CLAMP-TYPE BRAKE CHAMBER DATA
(Dimensions in inches)
Type | Outside Diameter | Rated Stroke | Maximum Stroke at Which Brakes Must be Adjusted |
|
16 | 6 3/8 | 2.50 | 2.0 ID Tags |
|
20 | 6 25/32 | 2.50 | 2.0 ID Tags |
24 | 7 7/32 | 2.50 | 2.0 ID Tags |
24 | 7 7/32 | 3.00 | 2.5 ID Tags |
30 | 8 3/32 | 3.00 | 2.5 ID Tags |
TIE ROD STYLE PISTON BRAKE CHAMBER DATA (Dimensions in inches)
Size | Outside Diameter | Maximum Stroke at Which Brakes Must be Adjusted |
|
30 | 6 1/2 | 2 1/2 |
BOLT TYPE BRAKE CHAMBER DATA (Dimensions in inches)
Type | Outside Diameter | Maximum Stroke at Which Brakes Must be Adjusted |
|
A | 6 15/16 | 1 3/8 |
B | 9 3/16 | 1 3/4 |
c | 8 1/16 | 1 3/4 |
D | 5 1/4 | 1 1/4 |
E | 6 3/16 | 1 3/8 |
F | 11 | 2 1/4 |
G | 9 7/8 | 2 |
ROTOCHAMBER DATA (Dimensions in inches)
Type | Outside Diameter | Maximum Stroke at Which Brakes Must be Adjusted |
|
9 | 4 9/32 | 1 1/2 |
12 | 4 13/16 | 1 1/2 |
16 | 5 13/32 | 2 |
20 | 5 15/16 | 2 |
24 | 6 13/32 | 2 |
30 | 7 1116 | 2 1/4 |
36 | 7 5/8 | 2 3/2 |
50 | 8 7/8 | 3 |
4. WEDGE BRAKES A. Reject vehicle if the wheel rotates with the service brake applied.B. Reject vehicle if the shoe travel exceeds 1116 inch.C. Reject vehicle if the shoe fails to move on application of the service brakes.5. BRAKE LININGS ORPADS A. Reject vehicle if the lining or pad is not firmly attached to the shoe.B. Reject vehicle if any lining or pad is contaminated with any amount of oil, grease, or brake fluid.C. Reject vehicle if, on a non-steering axle, the lining thickness is less than 1/4 inch at the shoe center for air drum brakes; 1/16 or less at the shoe center for hydraulic and electric drum brakes; and less than 1/8 inch for air disc brakes or at wear indicators.D. Reject vehicle if, on a steering axle, the lining thickness is less than 1/4 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 or electric brakes or at wear indicators.6. BRAKE DRUMS AND ROTORS AND CALIPERSA. Reject vehicle if there are any external cracks or if there are cracks that open upon brake application. Do not confuse short hairline heat cracks with flexural cracks.B. Reject vehicle if any portion of the drum or rotor is missing or rusted to the point of danger of falling away. All friction surfaces should be checked carefully for rust and deterioration. Reject vehicle if friction surface is rusted to the point of deterioration.C. Reject vehicle if any drum or rotor is worn beyond OEM discard specifications.D. Reject vehicle if cracks on the surface extend to the outer edges of the rotor.E. Reject vehicle if the rotor is damaged, or two or more grooves are worn beyond .090 inch (2.25 mm).F. Reject vehicle if any caliper is loose, does not meet manufacturers specification or is seized.G. Reject vehicle if any anchor plate is loose or a bolt is missing.H. Reject vehicle if any brake pad is damaged or contaminated.I. Reject vehicle if the adjustment cannot be made to meet the manufacturers specifications.J. Reject vehicle if any wheel seal is leaking. Slight seepage is not a cause for rejection.7. EMERGENCY/PARKING BRAKE SYSTEM A. Reject vehicle if any spring-operated brake on a vehicle or vehicle combination is not applied upon actuation of the emergency/parking brake control, including a drive line hand-controlled parking brake.B. Reject vehicle if the brake fails to hold.C. Reject vehicle if the brake fails to fully apply or release.D. Reject vehicle if the primary emergency/parking brake system is inoperative or if it is not as originally equipped. The system must be held in the applied position by energy other than fluid pressure, air pressure or electric energy.E. Reject vehicle if the indicator lamp (if so equipped) fails to illuminate.F. Reject vehicle if the mechanism binds or is inoperable.G. Reject vehicle if any cable is frayed, broken, or inoperable.H. Reject vehicle if the lining (if equipped) is less than 1/16 inch above the shoe on an external clamping type.8. HYDRAULIC BRAKES A. Reject vehicle if the master cylinder is leaking, loose, or the fluid level is 1/2 inch below the full line or, if not marked, 1/2 inch below the top.B. Reject vehicle if the cap is missing or loose, if the vent holes are plugged, or if the gasket is missing or damaged.C. Reject vehicle if the braked pedal travel from its free height to its depressed height is more than 65% of the total distance, or, if when holding steady pressure, the pedal travels to the floor or does not meet the manufacturer's specifications.D. Reject vehicle if the power assist unit fails to operate.E. Reject vehicle if any brake hose seeps or swells under application of normal pressure.F. Reject vehicle if the check valve is missing or inoperative.G. Reject vehicle if there is any visually observed leaking hydraulic fluid in the brake system.H. Reject vehicle if any hydraulic hose is abraded (chafed) through the outer cover-to-fabric layer.I. Reject vehicle if any fluid line or connection is leaking, restricted, crimped, cracked, or broken.J. Reject vehicle if the brake failure light or low fluid warning light is on or is inoperative.K. Reject vehicle if the hydraulic pump drive belt is loose, cracked, slipping, or missing.9. HYDRAULIC SYSTEM HOSES AND TUBING A. Reject vehicle if any line or hose is leaking, rusted to point of flaking, bulging, pitted, welded, cracked, flattened, not securely mounted, or has restricted sections. Surface rust is not cause for rejection.B. Reject vehicle if repairs to lines or hoses have been made with anything other than steel tubing, stainless steel, or other DOT approved lines or couplings.C. Reject vehicle if the connections are anything other than double flared.D. Reject vehicle if there is a hose with any damage extending through the outer reinforcement ply.E. Reject vehicle if a hose is severely chafed. If there is minor chafing, the hose should be re-routed so as to prevent further damage.F. Reject vehicle if any hose is routed in such a manner as to cause damage.G. Reject vehicle if hoses, lines, and fittings do not conform to manufacturer's original equipment standards.10. VACUUM SYSTEMS A. Reject vehicle if the vacuum system has insufficient vacuum reserve to permit two full brake applications after the engine is shutoff.B. Reject vehicle if a required low vacuum warning device is missing or inoperative.C. Reject vehicle if the lines or hoses are collapsed, broken, chafed, insecurely mounted, or less than 1.5 inches from any part of the exhaust system.D. Reject vehicle if the system is leaking.E. Reject vehicle if the clamps are missing, loose, or broken.F. Reject vehicle if any tank is missing, loose, damaged or leaking.G. Reject vehicle if the vacuum pump is loose.H. Reject vehicle if the vacuum pump drive belt is loose, cracked, excessively worn, or contaminated with oil.I. Reject vehicle if the vacuum pump is unable to achieve and maintain 18 inches of vacuum.11. HYDRAULIC SYSTEM WITH HYDRAULIC ASSIST A. Reject vehicle if no movement in the pedal is detected when starting engine.B. Reject vehicle if the warning indicator lamp is inoperable when the power steering pump is stopped.C. Reject vehicle if the pump reservoir is below the indicated "ADD" mark.D. Reject vehicle if hydro pump or any line or hose is leaking.E. Reject vehicle if the pump or belt is loose, cracked, or excessively worn.F. Reject vehicle if the electric motor fails to operate when the engine is not running.12. AIR ASSIST HYDRAULIC BRAKE SYSTEM NOTE: Air assist components of air assist hydraulic brake system are inspected as in the air brake section.
13. AIR SYSTEMS Compressed Air Reserve
A. Reject vehicle if the reservoir pressure is lowered more than 18 p.s.i. after one full brake application after the engine is shut down.14. AIR RESERVOIR, TRACTOR PROTECTION, AND TREADLE VAL YES A. Reject vehicle if any check valve is inoperable or missing.B. Reject vehicle if any check valve leaks or does not close.C. Reject vehicle if the air is not quickly exhausted through the exhaust port of the quick-release valve when the brakes are released.D. Reject vehicle if any valve mounting is un-secure or if the bracket is broken or loose.E. Reject vehicle if the air is not quickly exhausted through the exhaust port of the relay valve when the brakes are released.F. Reject vehicle if the tractor-protection control valve does not pop out or close at or above 20 p.s.i..G. Reject vehicle if air leakage is still noticeable at the emergency glad hand after the control valve has operated.H. Reject vehicle if any tractor protection valve leaks with the button out.15. AIR COMPRESSOR A. Reject vehicle if the air compressor mounting has any loose, cracked, broken, or missing bolts, brackets, braces, or adapters.B. Reject vehicle if compressor air intake cleaner is clogged enough to prevent proper air intake.C. Reject vehicle if any air compressor drive belt is worn, frayed, or loose.D. Reject vehicle if any air compressor pulley is cracked, broken, loose, or is bent or damaged so as to cause belt loss.E. Reject vehicle if any air tank mounting device such as straps, brackets or other hardware, is broken, missing, or loose.F. Reject vehicle if air compressor has excessive oil leaks or the air system is contaminated with oil.16. AIR PRESSURE BUILD UP TIME A. Test Procedure: With the trailer uncoupled and tires chocked, fully charge the system to the governor cutout pressure. Make one full brake application and note the air pressure reading on the gauge. Continue to reduce the air pressure by moderate brake applications to at least 10 PSI below the governor cut-in pressure. Release the brake and run the engine at the manufacturer's recommended rpm and determine the time required to increase the air pressure from the level achieved after one brake application to the governor cut-out pressure.B. Reject vehicle if the time required to build pressure from the level after one brake application to governor cut-out pressure is more than 30 seconds.17. AIR PRESSURE GOVERNOR A. Test Procedure: With the trailer line uncoupled and tires chocked, fully charge the system to its maximum capacity. Observe the gauge pressure and determine if the governor has a cut-out. With the engine running, make a series of brake applications and observe the gauge pressure to determine when the governor cuts in and out.B. Reject vehicle if the governor cut-out pressure is not between 115 and 135 p.s.i..C. Reject vehicle if the governor cut-in pressure is below 80 p.s.i..18. AIR PRESSURE WARNING DEVICE A. Test Procedure: With the air system fully charged, reduce the air pressure by moderate brake applications or by opening the drain cocks on the system. Observe the pressure at which the visual or audible warning device comes on.B. Reject vehicle if the air pressure gauge does not function properly. If vehicle was originally equipped with dual gauges, both must work.C. Reject vehicle if the air pressure warning device does not activate before pressure is lowered to 55 PSI or 1/2 of the governor cut-out pressure, whichever is less.D. Reject vehicle if the air pressure warning device does not continuously operate below activation pressure.E. Reject vehicle if either the visual or audible warning device fails to operate, if vehicle was originally equipped with both visual and audible devices.19. AIR PRESSURE LEAKAGE A. Test Procedure: With the air system fully charged and the trailer lines disconnected, stop the engine. With the brakes released, observe the pressure drop in one minute. After determining the pressure loss with the brakes released, make a full brake application and observe the pressure drop for one minute while the brakes are fully applied and the engine is off.B. Reject vehicle if the leakage rate with the brakes released in one minute exceeds 2 p.s.i. for single vehicles.C. Reject vehicle if the leakage rate with full brake application in one minute exceeds 3 p.s.i. for single vehicles.20. AIR PRESSURE RESERVE A. Test Procedure: With the air system fully charged, stop the engine and note the air pressure. Make one full brake application and then observe the pressure drop.B. Reject vehicle if the pressure drop is more than 20% of the first reading before the brakes are applied.21. AIR BRAKE COMPONENT A. Reject vehicle if any glad hand is damaged, cracked, corroded, insecurely mounted, or if any seal is broken.B. Reject vehicle if any air line is abraded to the first body ply cord, or if an air line is un-secure, flattened, damaged by heat, cracked, broken, kinked, or leaking.C. Reject vehicle if any air line is within 2 inches of the exhaust and is not protected by a heat shield.D. Reject vehicle if any air line does not meet OEM design standards.E. Reject vehicle if any hose is exposed at the first layer on a braided line.F. Reject vehicle if any air line connector does not meet OEM design standards.G. Reject vehicle if any air tank is missing, leaking, loose, or damaged so as to cause possible failure.H. Reject vehicle if any air tank bracket or strap is missing, cracked, broken, or if an inferior substitute has been used.I. Reject vehicle if any drain cock is missing, loose, leaking, inoperable, or does not meet OEM design standards.J. Reject vehicle if any moisture ejector (manual or automatic) is inoperable or is not present on each tank.K. Reject vehicle if any hose is improperly repaired (i.e., a splice made by sliding two hose ends over a piece of tubing and clamping the hose to the tube).L. Reject vehicle if brake tubing (plastic, copper or steel) is used in a frame-to-axle connection, unless it is factory original.M. Reject vehicle if the brake tubing is not securely attached to the frame and routed in such a way as to prevent damage to the line.N. Reject vehicle if any air tank is severely rusted to the point of possible failure.22. BRAKE MECHANICAL COMPONENTSA. Reject vehicle if any clevis pin is excessively worn, a cotter pin is missing, or an inferior substitute, such as a nut and bolt, has been used.B. Reject vehicle if any clevis yoke is excessively worn, cracked, broken, or bent.C. Reject vehicle if any pushrod is bent, broken, or misaligned.D. Reject vehicle if any slack adjuster is bent, broken, excessively worn, seized, or function improperly.E. Reject vehicle if any slack adjuster nut self-locking sleeve is seized or inoperable.F. Reject vehicle if the pushrod clevis pin hole setting is not in the same hole on the same axle, and the distance from the center of the cam to the hole is not the same on the same axle.G. Reject vehicle if any return spring is missing, stretched, or does not hold the lower roller to the cam.H. Reject vehicle if any roller is missing, has flat spots, or is the wrong size.I. Reject vehicle if any 'spider' is bent, loose, or if any bolts are missing.23. SELF-ADJUSTING SLACK ADJUSTERS A. Reject vehicle if any automatic brake adjusters or brake adjustment indicators are missing or inoperative.B. Reject vehicle if the indicators are not clearly visible.C. Reject vehicle if the adjustment is not within the manufacturer's specifications. All self-adjusting slack adjusters must be checked after brakes are adjusted to specifications.D. Reject vehicle if any manufacturer-installed self-adjusting slack adjuster was replaced with a non self-adjusting slack adjuster after October 20, 1994. C.M.R. 16, 222, ch. 1, § 222-1-200, subsec. 222-1-200-05