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hgv_manual | 0 | 1 | 95 | 14 | Issue Date February 2017
Section B Page i
Heavy Goods
Vehicle (HGV)
Inspection Manual
| [
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Heavy Goods Vehicle Inspection Manual
About this Manual
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Purpose
This manual explains to everyone engaged in the practical work of vehicle
examination and maintenance:
• The application of specific relevant requirements.
• The procedures and standards to be used.
• The deficiencies.
• The deficiency categorisation.
The manual is not a legal interpretation of Regulations, nor does it necessarily lay
down standards for rejection elsewhere.
Layout of Inspection Manual
The page layout for each inspection item consists of an Application section; this
section will contain the application criteria. Following this will be the Procedure and
Standards section where any procedures specific to the section will be contained
as well as any notes relevant to the standards to apply. The remainder of the
page(s) will be split between the Deficiency and the Deficiency Category columns.
Procedures
The procedures given here assume that only parts of a vehicle which can readily
be seen without dismantling are to be examined. However, it may be necessary to
ask the driver to remove wheel embellishers or panels where it is not otherwise
possible to inspect safety critical items.
Vehicle combinations will not normally be separated for the purposes of the test
although it will be necessary to disconnect and reconnect airlines as directed.
Minimum Standards
It must be emphasised that these are minimum acceptable standards, which do not
necessarily allow for further deterioration when the vehicle is in service.
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About this Manual
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Deficiency Categorisation
Deficiencies found during the test shall be categorised in one of the following
groups:
• Minor – deficiencies having no significant effect on the safety of the
vehicle/trailer or impact on the environment and other minor non-
compliances. If only defects of a minor nature are present, a pass must be
recorded.
• Major – deficiencies that may prejudice the safety of the vehicle/ trailer,
have an impact on the environment, put other road users at risk or other
more significant non-compliances.
• Dangerous – deficiencies constituting a direct and immediate risk to road
safety or having an impact on the environment.
Acceptance For Test
A condition for accepting vehicles/trailers for test require a VTG6 plate or VTG7 certificate or copies
thereof. For vehicles where no plates or certificates are issued a technical record must be in place
before a test can commence.
This does not apply however to trailers presented for their first ever annual test.
Plating documents for these trailers will be issued on successful completion of
this "first test”.
Other conditions for accepting vehicles for test include:
• A trailer must be accompanied by a suitable drawing vehicle.
• The vehicle chassis number or DVSA issued trailer identification mark
must be permanently fixed to the vehicle in an accessible, easy to read
position.
• The vehicle/trailer must be clean enough to allow the component parts to
be inspected.
• The vehicle/trailer must not present a health & safety hazard to inspect.
• The vehicle/trailer must be appropriately loaded.
If you are in doubt regarding any of the above, it is recommended that you
contact the Driver and Vehicle Standards Agency Contact Centre for advice.
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Acceptance For Test (continued)
Vehicles must be fitted with their bodies and should not be accepted for test
without them. This does not include bin carriers, skeletal vehicles for carrying
containers or demountable bodied vehicles.
The Inspection
Each inspection has been allocated a number, which is given at the top of the
page.
Not all inspection numbers have been allocated.
The requirements of each inspection will be found in Schedule 3 of the Goods
Vehicle (Plating and Testing) Regulations.
After The Test
On completion of the test, copies of the smoke test and brake test reports should
be issued, together with (if applicable) a refusal to issue a certificate. The refusal
will refer to the deficiencies identified, which are considered to be below the
minimum standard.
Assessment of Component Condition
It is not practicable to lay down limits of wear and tolerances for all types of
components on different models of vehicle, or to define acceptable amounts of
damage, deterioration and effectiveness. Testers are therefore expected to use
their knowledge, experience and judgement in assessing whether the condition
of a component has reached the stage where it is obviously adversely affecting
its functionality or likely to adversely affect the roadworthiness of the vehicle.
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Scope of Inspections
The scope of the inspections in this manual does not cover all the
requirements of The Road Vehicles (Construction and Use)
Regulations and The Road Vehicles Lighting Regulations. It may be
noted that some standards in this inspection manual may differ from
that of type-approval, this is because this manual is covered and
updated by different regulations.
Dual controls on vehicles will be inspected in the same manner as the
primary controls although there will be no separate brake performance
check.
Health and Safety
Drivers presenting vehicles for test must follow the instructions given
by Driver and Vehicle Standards Agency staff. Radios and
telephones must not be used whilst vehicles are undergoing test.
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Heavy Goods Vehicle Inspection Manual
Revision Record
01/07/2025
1 of 2
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Section
Number
Section Title
Description of Change
Revision
Date
About this Manual
Page 2 - Deficiency Categorisation – last sentence from minor
deficiencies amended to cater for electronic test certification.
01/06/2024
03
Seat Belts &
Supplementary
Restraint Systems
Page 2, note in procedure and standards for cuts and
damage assessment is updated to clarify the importance
of tensile strength.
Page 2, note added to procedure and Standards “Air bags
are not a mandatory fitment, the deficiency for air bag
missing must only be used where it is obvious the vehicle
had an air bag fitted and it is now missing.
Page 2 some information moved to page 3.
01/06/2024
07
Size and Type of
Tyres
Page 1, note added to use markings encountered “some
tyres may be branded for a tyre recommended use while still
suitable for other applications”.
01/06/2024
23
Glass and View of
the Road
Page 2, note added to clarify the standard to apply for view to
front on dash mounted monitors will dependant on the
function that the system provides.
01/06/2024
26
Speedometer/
Tachograph
Page 1 and 2, information layout reformatted with reference
to analogue and digital tachographs removed. Removed
duplicated note for the checks on DIL switch covers.
01/06/2024
42
Electrical Wiring
and Equipment
Page 1, note added to procedure and standard “A trailer
electrical socket with a defective or missing cover flap that
incorporates a lug and spring to hold the plug in place is not
considered to be a defect.”
01/06/2024
63
Lamps
Page 2, note added in respect of inoperative non obligatory
lamps.
Page 2 reversing lamps fitment note “ but all must work”
removed.
01/06/2024
66
Direction Indicators
and Hazard
Warning Lamps
Page 2, note added in respect of inoperative non obligatory
lamps.
01/06/2024
Section
Number
Section Title
Description of Change
Revision
Date
About this Manual
Page 4 of 4 – Scope of Inspections – Added to paragraph in
respect of regulatory requirements which update this manual
compared with type-approval.
01/04/2025
Interpretation of
Terms
Page 2 added Note: Fuel tanks and gas cylinders will only be
subject to visual inspection for corrosion.
01/04/2025
7
Size and Type of
Tyres
Page 10 of 10 – Deficiency 1a (ii) After the words ‘axle
weight and is loaded’ new wording is added which states ‘at
least 10%’.
01/04/2025
09
Sideguards, rear
under-run devices
& bumper bars
Complete re-write of the section, improving flow.
Incorporated new list of exempted vehicles for sideguards
from 01/04/25.
Added pictures of the sideguard area for different vehicles as
well as a new picture for lateral projection.
Information for BSIS radar devices fitted in sideguard gaps.
01/04/2025
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Interpretation of Terms used in the Manual
Articulated Vehicle
An articulated vehicle is a motor car or heavy motor car with a trailer so attached that part
of the trailer is superimposed on the drawing vehicle and, when the trailer is uniformly
loaded, not less than 20% of the weight of its load is borne by the drawing vehicle.
Corrosion
The effect of corrosion on the safety of the vehicle depends on:
• Its extent.
• The function of the section on which it has occurred.
A small amount of corrosion on an important part of the vehicle structure can make a
vehicle unsafe where it destroys the continuity of the load bearing structure.
On the other hand, heavy corrosion of unimportant sections may have no effect on the
vehicle safety.
Corrosion Assessment
The inspection should determine whether excessive corrosion exists first by visual
inspection and then by finger and thumb pressure.
If necessary careful scraping or light tapping of the area is permitted.
Corrosion affected heavy gauge metal may be tapped harder than light gauge, but
unwarranted force and damage must be avoided.
Corrosion Failure Criteria
Any part of a load bearing member or load bearing panelling should be refused if it is
weakened by corrosion to the extent that:
• By finger and thumb pressure it does not feel rigid, or
• It crumbles to leave a hole, or
• When tapped there is penetration, or it causes the metal to crumble or disintegrate.
Note: Fuel tanks, air tanks and gas cylinders will only be subject to visual inspection for
corrosion.
Cracked
A flaw or split in a component.
Damage
When assessing the extent of damage, it is important to consider whether the
performance of the component/system will be impaired or if the component/system is
likely to fail prematurely.
Damage fulfilling either of these criteria is not acceptable and will be a deficiency.
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Interpretation of Terms used in the Manual
Deteriorated
This will be a deficiency if the component or system is weakened to such an extent that
it can no longer adequately perform its function.
Distorted
This will be a deficiency if the component or system is distorted to such an extent that it
can no longer adequately perform its function.
DGVW
Design Gross Vehicle Weight – the maximum gross weight a vehicle was designed to
operate at by the manufacturer.
DTAW
Design Total Axle Weight – the maximum total axle weight a vehicle was designed to
operate at by the manufacturer.
EV (Electric Vehicle)
A vehicle that is powered by electric power train only. A vehicle with a hydrogen fuel cell
should be considered an electric vehicle.
Excessive travel
An abnormal amount of movement which clearly indicates that a component has
reached a stage when it requires remedial action to enable it to either:
a. operate effectively as designed, or
b. prevent it from reaching the end of its permitted travel, or
c. prevent it from exceeding manufacturer’s known maximum permitted limits.
Excessive wear
A component which is worn to such an extent that it is either:
a. likely to fail, or
b. clearly not functioning effectively as designed, or
c. visibly worn beyond manufacturers’ known permitted limits, or
d. likely to affect the operation or condition of another safety related component.
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Interpretation of Terms used in the Manual
First use dates
Throughout this manual we have used the terms “before” and “from” when referring to
first use/manufactured dates. The term “from” should be regarded to be ‘on or after’ a
certain date. Where there is a first use date quoted for a motor vehicle this will not
normally apply if the vehicle was built more than 6 months before that date.
Forward Control Vehicle
Is a vehicle the configuration of which:
• more than half of the engine length is rearward of the foremost point of the
windshield base and;
• the steering wheel hub is in the forward quarter of the vehicle length.
Fouling
This will only be a deficiency if contact of two parts is likely to cause damage to or
restrict the movement of a component.
Fractured/broken
Gap, opening or rupture where separation has taken place.
Front steered axle
Any axle(s) deemed to be forward of the chassis midpoint and directly controlled by the
motor vehicle steering system.
HEV (Hybrid Electric Vehicle)
A vehicle powered by a power train that consists of both an internal combustion engine
and an electrical energy/power storage device.
Inappropriate Modification
A modification to a component which stops or severely affects the functionality of the
component (also see unsafe modification).
Insecure
The term “insecure” is used many times throughout this manual to describe a defective
condition. This term should be taken to mean either:
• a component has relative movement (looseness) at its fixings where there should
be none, or
• a component has relative movement (looseness) to an associated component
where there should be none, or
• a safety critical component is not safely or completely attached at its fixing or to
an associated component.
Certain components, such as wheel studs/nuts, body mountings etc. have specific
criteria detailed in the inspection manual.
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Interpretation of Terms used in the Manual
Obligatory/Mandatory
Required to be fitted by law.
Semi-trailer
A trailer which is constructed or adapted to form part of an articulated vehicle.
Trailer
Where the term trailer is used in this manual it refers to all types of trailers and semi-
trailers.
Type Approved Vehicle
A vehicle manufactured from 1 October 1982 and first used from 1 April 1983 and has
been issued with a Type Approval Certificate of Conformity, a Ministers Approval
Certificate or a Type Approval Certificate issued by an EU Member State.
Type Approved
A component or system fitted to a vehicle which has been issued with a Type Approval
Certificate or Certificate of Conformity or built to an approval standard which shows that
the system or component complies with the requirements of an EU Directive or ECE
regulation.
If the presenter claims that the vehicle is fitted with type approved equipment which
complies with the requirements of an EC directive and has no documentary evidence,
consideration must be given to the following:
• annual test standards should not exceed those of type approval
• does the component or system appear to have been modified, replaced or damaged
Where doubt exists, the benefit should be given to the presenter.
Unsafe Modification
Modifications to vehicles must be assessed on their merits, taking account of the nature
of the modification and whether the component is safety critical.
The main criteria to be used are:
• whether the modification adversely affects the roadworthiness of the vehicle, or
• is likely to cause injury (such as modification to the body), or
• has a disproportionately adverse effect on the environment.
Vehicle
Where the term vehicle is used in the application section of this manual it refers to all
types of motor vehicle.
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Interpretation of Terms used in the Manual
Vehicle Category (Definition used in the Community Directive)
G: Off-road vehicles
N2: Vehicles used for the carriage of goods and having a DGVW exceeding 3,500 kg
but not exceeding 12,000kg.
N3: Vehicles used for the carriage of goods and having a DGVW exceeding 12,000kg.
O2: Trailers with a DTAW exceeding 750kg but not exceeding 3500 kg.
O3: Trailers with a DTAW exceeding 3,500 kg but not exceeding 10,000kg.
O4: Trailers with a DTAW exceeding 10,000kg.
Category T tractors for the purpose of this inspection manual means those that are:
(a) capable by their design and construction of exceeding 40 kilometres per hour,
(b) used for the haulage of a load or burden more than 15 miles from their operating
base, and
(c) where the haulage of the load or burden is not in relation to an agriculture,
horticulture or forestry operation
Vehicles of a specialised design or use characteristics
Vehicles designed/constructed and or used for specialist tasks such as cranes, category
T vehicles or road construction vehicles may be unable to comply with some or all of the
requirements for sideguards, rear under-run, spray suppression, conspicuity or lighting
positional requirements.
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List of Inspections
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1
*Registration Plate
2
Not allocated
3
*Seat Belts and Supplementary Restraint
Systems
4
Not allocated
5
*Exhaust Emissions
6
Road Wheels and Hubs
7
Size and Type of Tyres
8
Condition of Tyres
9
Sideguards, Rear Under Run Devices
and Bumper Bars
10 Spare Wheel and Carrier
11 Vehicle to Trailer Coupling
12 Trailer parking, Emergency Brake and Air
Line
Connections
13 Trailer Landing Legs
14 Spray Suppression, Wings and Wheel
Arches
15 *Cab Security
16 *Cab Doors
17 *Cab Floor and Steps
18 *Seats
19 Security of Body, Containers and Crane
Support
Legs
20 Condition of Body
21 Not Allocated
22 *Mirrors and Indirect Vision Devices
23 *Glass and View of the Road
24 Not allocated
25 *Windscreen Washers and Wipers
26 *Speedometer/Tachographs
27 *Horn
28 *Driving Controls
29 Not allocated
30 *Steering Control
31 Not allocated
32 Not allocated
33 *Speed Limiter
34 *Pressure/Vacuum Warning and Build Up
35 Not allocated
36 *Hand Lever Operating Mechanical Brakes
and Electronic Park Brake Controls
37 *Service Brake Pedal
38 Service Brake Operation
39 Hand Operated Brake Control Valves
40 Not allocated
41 Condition of Chassis
42 Electrical Wiring and Equipment
43 *Engine and Transmission Mountings
44 Oil Leaks
45 Fuel Tanks and Systems
46 *Exhaust Systems and Nuisance
47 Not allocated
48 Suspension
49 Not allocated
50 Not allocated
51 Not allocated
52 Not allocated
53 Axles, Stub Axles and Wheel Bearings
54 Steering
55 Not allocated
56 Not allocated
57 Transmission
58 Additional Braking Devices
59 Brake Systems and Components
60 Not allocated
61 Not allocated
62 Markers and Reflectors
63 Lamps
64 Not allocated
65 Not allocated
66 Direction Indicators and Hazard Warning
Lamps
67 *Aim of Headlamps
68 Not allocated
69 Not allocated
70 Not allocated
71 Service Brake Performance
72 *Secondary Brake Performance
73 Parking Brake Performance
74 Other Dangerous Defects
*Inspection does not apply to trailers
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Standards for Prohibition Issue at Statutory Test
This provides a standard for the issue of Prohibition Notices where dangerous
deficiencies are observed during statutory tests.
The aim of the policy is to:
• Protect the public and other road users from unsafe vehicles where very
dangerous deficiencies have been observed during test.
• Let operators know the rules so that they know and understand the
standards for prohibition issue at test.
• Ensure consistency of approach.
• Preserve a balance between providing a flexible, customer focused,
testing service and providing the public with protection from loss or injury
from vehicles being used on public roads with serious roadworthiness
defects.
• Provide information about such occurrences to DVSA Enforcement, and to
Traffic Commissioners.
The approach, in principle, is to apply the following:
• Where a dangerous deficiency is marked with an asterisk * the examiner
will be required to assess the severity of the defect in line with the
deficiency criteria detailed in the table contained within the following
pages, before deciding whether to issue an immediate prohibition.
• Where a dangerous deficiency is NOT marked with an asterisk; this will
result in the issue of an immediate prohibition.
‘S’ Marked Prohibitions:
Prohibitions issued for defects found at the time of test will be endorsed as ‘S’
mark indicating there is a significant failure of roadworthiness compliance and
maintenance, unless in the issuing Examiner’s opinion the defect could not have
been foreseen (i.e. a defect arising on the way to the Testing Facility).
Note:
Where an Exemption notice is issued to permit prohibited vehicles to proceed to
a place of repair under controlled conditions the conditions of movement must be
detailed on the notice. Examiners will issue an Exemption notice only if in their
opinion the vehicle can be moved to such a place without risk to public safety.
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Standards for Prohibition Issue at Statutory Test
Manual Reference
Deficiency Criteria
Deficiency
IM 59
Brake systems and
components
A brake back plate insecure or seriously weakened.
A brake disc or drum missing, failed or failure
imminent.
3a(ii) *
IM 71
Service Brake
Performance
The vehicle as presented, poses an immediate
danger to road safety.
Efficiency significantly below legal requirements.
Before issuing, the examiner must consider whether
the vehicle, as presented, poses an immediate
danger to road safety.
1d (iv)*
1d (v)*
IM 72
Secondary Brake
Performance
The vehicle as presented, poses an immediate
danger to road safety.
Efficiency significantly below legal requirements.
Before issuing, the examiner must consider whether
the vehicle, as presented, poses an immediate
danger to road safety.
1b (ii)*
1c*
IM 73
Parking Brake
Performance
Before issuing the examiner must consider whether
the vehicle as presented, poses an immediate
danger to road safety.
Efficiency significantly below legal requirements.
Before issuing, the examiner must consider whether
the vehicle, as presented, poses an immediate
danger to road safety.
1a (ii)*
1b*
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01 Registration Plate
Application
This inspection applies to all registered motorised vehicles.
Procedure and Standards
A registration plate should be easily legible to a person standing approximately 20m from the
front/rear of the vehicle. Where a registration plate is obviously obscured by objects such as tow
bars this will be a deficiency under 2b.
The registration plate must be checked for presence and security at the front and rear of the
vehicle. The registration mark must be checked for presence and legibility.
A registration mark with characters which are obviously incorrectly spaced (see examples), mis
formed or uses misplaced fixing bolts to alter the registration mark appearance, will be deemed to
be not in accordance with the requirements.
AB 19 NGF
M700N KV
Registration plates may display UK national flags or lettering on the left-hand side, and they may
also show a green flash here to indicate that the vehicle is electric.
Deficiency
Deficiency
Category
1
A registration plate:
a.
missing.
Major
b.
insecure.
Major
2
A registration mark:
a.
missing.
Major
b.
illegible.
Major
c.
not in accordance with the requirements.
Major
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03 Seat Belts & Supplementary Restraint Systems
Seat belt webbing must be assessed for cuts, damage, fluffing, fraying and any evidence of
overstretching. Assessors must ensure that seat belt operation is not affected by any such
damage. Any signs of overstretching will be a deficiency.
When assessing cuts or damage:
• Lateral cuts or damage on either edge of the webbing in excess of 2mm are likely to
reduce the webbing strength significantly and will be deemed a deficiency.
• Lateral cuts or damage away from the webbing edges have a lesser effect on the tensile
strength of a belt, only cuts or damage obviously in excess of 4mm shall be considered a
deficiency.
• Vertical cuts or damage travelling along the belt length will have a lesser effect on the
tensile strength than lateral cuts across the belt as there is less of a tendency to tear. A
deficiency here should only be considered where there is substantial damage to such an
extent that the belt strength is obviously seriously reduced.
On retracting seat belts, check that with the mechanism fastened and the seat adjusted to its
rearmost position, excess webbing is wound into the retracting unit. If there is doubt about the
operation of the retracting unit, this check should be carried out with the seat unoccupied.
Some types of retracting belt might need manual help before they retract.
Operate the release mechanism while pulling on the belt to check that the mechanism
releases when required.
Pull the sheaths aside if this can be done without causing damage.
Some vehicles have seat belts which will not release the inertia aspect of the seat belt
unless the ignition is switched on. Ensure the park brake is applied, and the gears are in the
neutral position before switching on the ignition. Owing to the height of cabs on many commercial
vehicles this inspection should be performed with the inspector sat in the appropriate seat.
Floor mounted anchorages may need to be inspected from underneath the vehicle.
Where a belt is fitted with no corresponding seat or if there is a buckle/stalk but no
corresponding belt, it is NOT to be considered a seat belt for the purpose of this inspection.
The SRS malfunction indicator lamp (MIL) may display a symbol similar to that below, one
depicting a person wearing a seat belt or alternatively the letters ‘SRS’.
A passenger air bag, which has been switched off, is not a deficiency.
Air bags are not a mandatory fitment, the deficiency for air bag missing must only be used
where it is obvious the vehicle had an air bag fitted and it is now missing.
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03 Seat Belts & Supplementary Restraint Systems
Seat belt load limiters are used on some vehicles to minimise seat belt inflicted injury in
particularly violent collisions.
This is generally achieved by releasing a little more excess belt webbing when a great deal of
force is applied to the belt.
The simplest type of load limiter is a fold sewn into the belt webbing. The stitches holding the fold
in place are designed to come apart when a high amount of force is applied to the belt, thereby
releasing an extra bit of webbing.
More advanced load limiters rely on a torsion bar in the retractor mechanism, which cannot
usually be readily seen or tested.
Seat belt pre-tensioners may be fitted to some seat belts. Once activated a warning device may
display.
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05 Exhaust Emissions
Application
This inspection applies to all Compression Ignition engine vehicles.
Vehicles first used before 1 January 1980 will be subject to a visual examination only, see item 2 in
Procedure & Standard and Deficiency sections for more details.
For Hybrid Electric Vehicles (HEV) see ninth bullet point below.
The inspection of the engine MIL
applies to diesel fuelled vehicles first used from 1 July
2008. The engine emission system (EES) MIL
is only part of the test where a vehicle is not
fitted with the commonly recognised engine MIL.
The engine MIL inspection does not apply to dual fuelled vehicles.
Procedure and Standards
Compression Ignition Engines:
• Exhaust emissions must be tested using an approved and calibrated smoke meter.
• Only in exceptional circumstances where it is not possible to use a smoke meter will a
visual check be carried out (visual tests will not apply to Fast Pass or vehicles submitted for
Low Emission Testing).
• If the exhaust has been deliberately modified to prevent the smoke meter from being
used a VTG 12 must be issued refusing to complete the test because the exhaust smoke
emissions test cannot be carried out.
• Twin exhaust systems, with or without a balance pipe - both systems must be
individually tested for smoke emissions. It may be necessary to purge the exhaust system
again prior to the second check.
• Supercharged engines should be tested by selecting the non-turbocharged option on the
smoke meter.
• The test procedure for turbocharged and non-turbocharged engines is the same.
• It is not normally sufficient to run the engine with the vehicle stationary to warm it up to
temperature, so the emissions should be tested as soon as possible after the vehicle
arrives at the test site.
• With some types of smoke meter care must be taken to ensure that the probe is correctly
aligned to the exhaust gas flow (reference to meter manufacturer’s instruction may be
necessary).
• HEVs do not require a metered smoke test or a visual smoke test. However, if during the
test excessive smoke is observed, this will be a deficiency under item 2b.
Some smoke meters (DSM) may fail to trigger a reading when testing modern vehicles fitted
with low emission diesel engines, which produce very low levels of smoke. If the smoke meter does
not register a reading or shows an error reading, then irrespective of whether the DSM produces a
printout a record of this must be made and produced on the test documentation. Where the DSM
will not produce a printout, the record must state that the emissions limits were tested and met but
the DSM could not register the reading.
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05 Exhaust Emissions
Air Fuel Ratio Control (AFRC) fitted to Caterpillar engines. When the engine is stopped the
control goes into an excess fuel position. When the engine is restarted the inlet manifold pressure
necessary to reset the AFRC into its normal running position is normally greater than that generated
during the free acceleration test. Vehicles should therefore either be checked at the start of the test
if the engine has not been stopped or at the end of the test where the vehicle should be driven on
against the load of a partially applied brake sufficient to reset the AFRC prior to conducting the test.
If a vehicle fails the test because the exhaust is holed the emissions must be rechecked when
the vehicle is retested.
Remember to issue a printout.
1.
Free acceleration test using smoke meter
1a.
i. Check that the engine is at or near normal operating temperature.
ii. Purge the inlet and exhaust systems fully by holding the engine speed steady at just below
maximum governed speed for 30 seconds.
iii. Select the appropriate test programme on the smoke meter.
iv. Follow the meter prompts; depress the accelerator pedal quickly but not violently, to reach
full fuel position in less than 1 second. Hold it there until a release prompt is given. If, at the
end of the 1st acceleration, the smoke meter value is no more than the appropriate opacity
limit required for the vehicle, it will be deemed to have met the test limit.
v. After the first acceleration read the smoke level displayed on the meter. If it is greater than
the opacity limit for the vehicle, further accelerations will be required up to a maximum of
six.
1b.
Assess visually whether the smoke emitted from the exhaust regardless of the measured
density, is likely to obscure the vision of other road users.
2. Visual emission test
2a.
i. Only in exceptional circumstances where it is not possible to use a smoke meter will a
visual check be carried out. The visual test is only to be used when it is not possible to use
the smoke meter or where risk to health and safety would arise. The procedure is the same
for supercharged, turbocharged and non-turbocharged engines.
ii. With the engine at or near normal operating temperature check the density of the exhaust
emission visually.
iii. Ask the driver to depress the accelerator pedal quickly but not violently, to reach full fuel
position in less than 1 second. Immediately release when the engine reaches its maximum
governed speed, allow the engine to return to idle speed.
iv. Ignore smoke from the first acceleration.
v. Repeat up to a maximum of six times if necessary, until the exhaust smoke is considered
to be acceptable for two successive accelerations.
2b.
Assess whether the smoke emitted from the exhaust, regardless of the measured density,
is likely to obscure the vision of other road users.
| [] | [] | [] | [] | train |
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05 Exhaust Emissions
Note: The criterion is density and not volume of smoke. The description `dense smoke’ includes
any smoke or vapour, which largely obscures vision.
Manufacturer’s plate value means either the value displayed on the VIN plate or a separate
plate or sticker, which is likely to be within the engine compartment. The plate or sticker may be
marked 24 R followed by a number to indicate the smoke limit (such as 0.24 in the example
below). It’s usually displayed in a box and often positioned in a corner of the VIN plate. The plate
value must be used where available and may be of a value lower or higher than the default value.
Where more than one manufacturer’s plate value is shown on a vehicle the less onerous limit
must be used.
Generally, the engine MIL takes the form of the commonly recognised engine symbol
.
However, some vehicles may only have been manufactured with an EES lamp
in which case
this would be subject to test. Examiners must be certain that a deficiency exists before applying
deficiency 5.
Where a vehicle is fitted with an engine MIL any illumination of the EES lamp is to be disregarded.
For all vehicles check the presence and condition of any emission control systems fitted as
standard.
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05 Exhaust Emissions
Deficiency
Deficiency
Category
Compression Ignition Engines
1
Statutory Smoke Meter Test:
a.
After a total of six accelerations have been completed, the
average smoke opacity recorded for accelerations 4, 5
and 6 is more than:
For vehicles used before 1 July 2008:
i.
The level specified by the manufacturer’s plate or
2.5m-1 for non-turbocharged engines where the
plate value is not available.
ii.
The level specified by the manufacturer’s plate or
3.0m-1 for turbocharged engines where the plate
value is not available.
For vehicles first used from 1 July 2008:
iii.
The level specified by the manufacturer’s plate or
1.5m-1 for all CI engines where the plate value is
not available.
For vehicles first used from 1 January 2014:
iv.
The level specified by the manufacturer’s plate or
0.7m-1 for all CI engines where the plate value is
not available.
Major
b.
The exhaust emits excessive smoke or vapour of any colour, to
an extent likely to obscure vision.
Dangerous
2
Statutory Visual Test:
a.
After a maximum of six accelerations the exhaust emits
smoke of a level greater than that of equivalent metered
levels.
Major
b.
The exhaust emits excessive smoke or vapour, of any
colour, to an extent likely to obscure vision.
Dangerous
All vehicles
3
Emission control equipment fitted by the manufacturer
absent, or obviously defective or shows any signs of
obvious tampering.
Major
4
A vehicle equipped with a Diesel Particulate Filter shows
any visible signs of smoke.
Major
5
Engine MIL inoperative or indicating a malfunction.
Major
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05 Exhaust Emissions
Low Emissions Vehicles (LEV) Smoke meter test
The LEV check is not part of the statutory test requirement.
1. Select appropriate LEV limit. Carry out Method of Inspections listed at 1.a
procedures I, II and III only.
2. Following meter prompts carry out three acceleration tests. Depress the accelerator
pedal quickly but not violently, to reach full fuel position in less than 1 second. Hold
it there until a release prompt is given. At the end of the 3rd acceleration the smoke
meter will display the average smoke value and test result. If the LEV value is not met
and the meter readings are above the statutory limits, further accelerations up to a
maximum of six may be prompted by the meter.
A vehicle will pass the LEV metered test if the opacity level is no greater than:
0.2m-1 for all vehicles fitted with a particulate trap.
0.4m -1 vehicles fitted with an unmodified Euro -2 engine.
0.8m -1 vehicles fitted with an unmodified Euro -1 engine.
1.0m-1 vehicles retro-fitted with a Euro -2 engine.
| [] | [] | [] | [] | train |
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06 Road Wheels and Hubs
Application
This inspection applies to all road wheels and hubs apart from spare wheels.
Procedure and Standards
Where possible, wheel nuts will be lightly tapped with a hammer to check for looseness,
but any other evidence such as rust marks or elongation of bolt/stud holes must also be taken
into account.
A nut or stud is considered to be “loose” if it is not obviously carrying out its function of
clamping the wheel to the hub/wheel flange.
With some vehicles it is not possible to see the road wheels completely from ground level,
especially with twin wheels and where the body hides part of the wheels. In such cases the
vehicle must be moved to expose hidden parts of the wheels or examined from underneath.
Whenever possible, presenters should remove wheel embellishers; remove visual security
indicators, if they prevent a full examination. Where this cannot be accomplished, continue to
inspect the vehicle and a record must be made on the test documentation to state that the
embellishers were not removed.
A 'wheel flange' is a component which is positioned between the road wheel and the hub which
contains the wheel studs.
Capacity Limitations of 11.75 x 22.5 Alcoa Aluminium Wheels.
Wheels with part number 813520/813523 may be stamped on the inside of the wheel, opposite
the valve, with a maximum load rating of 4250kg or 4500kg and those with part number
813530/813533 with a rating of 4500kg. It has been agreed that wheels with these part numbers
and maximum load ratings are suitable for a maximum axle weight of 9150kg.
Kronprinz wheels fitted to the Volvo FL L 4x2 rigid and FL 6H 4x2 rigid, are capable of carrying
higher loads than those shown on the wheels. The wheels can be identified by the following
markings stamped on the wheel:
Wheel brand name
Kronprinz
Clamping type
M20
Place of manufacture Made in France
Designation
19.5 x 7.50HOS56 E-DOT
Wheel load index
144/142
Volvo part number
20946506
The wheel is capable of carrying a load equatable to a 145/143. Please be aware of the
increased load capacity should you observe these wheels at the annual test. This weight increase
is applicable to all vehicles equipped with these wheels, not just Volvo.
Capacity limitation of a wheel marked with a load index
If a wheel is marked with a load index which indicates that the maximum load is lower than is
required to support the axle load, this will be a deficiency under 2.f.
Wheels not marked with a load index or load marking must be assumed to be capable of
carrying the axle weight.
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06 Road Wheels and Hubs
2
A wheel:
a.
(i)
with any visible elongation of a stud hole.
Major
(ii) with any visible elongation of a stud hole where secure fixing
of the wheel is affected.
Dangerous
b.
(i)
badly damaged or distorted (including damaged by the
corners of a wheel nut cutting into the material of the wheel).
Major
(ii) badly damaged or distorted (including damaged by the
corners of a wheel nut cutting into the material of the wheel)
where secure fixing of the wheel is affected.
Dangerous
c.
not compatible with its fixings.
Major
d.
cracked (except at the bridge over the valve), weld breaking
away or an inadequate repair.
Dangerous*
e.
made of aluminium alloy repaired by welding.
Major
f.
with a load rating less than that required to support the
maximum permissible (GB) axle load
Major
3
A hub:
a.
(i)
cracked, badly damaged, or with a half shaft or wheel flange
bolt, stud or nut loose or missing.
Major
(ii) cracked, badly damaged, or with half shaft bolts or wheel
flange bolts, studs or nuts loose or missing where secure
fixing of the wheel is affected.
Dangerous
b.
with clearance between a spigot mounted wheel and the hub
spigots that exceeds 3mm across the diameter.
Major
c.
(i)
with a wheel retaining nut or stud missing or loose or
obviously not fulfilling the function of clamping the wheel to
the hub.
Major
(ii) with multiple wheel retaining nuts or studs missing or loose or
obviously not fulfilling the function of clamping the wheel to
the hub.
Dangerous
d.
with a spigot wheel nut washer cracked.
Major
e.
with a wheel locating spigot or dowel missing.
Major
| [] | [] | [] | [] | train |
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07 Size and Type of Tyres
Application
This inspection applies to all tyres, apart from spare tyres.
Procedure and standards
The use markings most likely to be encountered are 'FRT' which indicates that the tyre is not
suitable for use on a driven axle or front steered axle. Tyres marked 'TRAILER USE ONLY' are only
suitable for use on trailers, some tyres may be branded for a tyre recommended use while still
suitable for other applications. Tyres marked with a direction arrow pointing in the wrong direction
should not be refused.
Tyres are usually identified by their nominal section size followed by the rim diameter e.g.
10.00-20,750-16, etc (the majority of modern tyres carry millimetric markings e.g. 205-16 etc). For
identification of sidewall markings refer to the diagram at the end of this section. All tyres on an
axle must be of the same nominal size. If a tyre is dual marked one of the markings must be the
same as the markings on the other tyres on the axle.
There are still a number of high load capacity tyres in use which are marked with a code to
indicate the tyre size and capacity e.g. a 10.00-20 16 ply tyre may be marked D20 or 4-20 (a full list
of these tyres is given at Table 1).
If tyres marked with a load capacity index are fitted the maximum permissible axle Load for
normal use can be found in Table 2 at the end of this section. The Load Index (LI) may consist of
one or two numbers e.g. 154 or 146/143. Where two numbers are displayed the first refers to the
use of the tyre in single formation and the second in twin formation. Reference to the table shows
that the maximum loads for this tyre are 6000kg in single formation and 10900kg in twin formation.
Note: The load index applies to GB plated weights.
If a load index is not shown the carrying capacity of a tyre can be determined from the Ply Rating.
The load capacity of ply rated tyres is shown at Table 3. If no ply rating can be found on the tyre it
should be assumed to have the lowest load capacity listed for that size of tyre.
This information relates to tyres used without any restriction (i.e. with tyre use symbol 2B indicated
on the plate or plating certificate). There are three other categories of vehicle use which allow tyres
to be operated at lower speeds and higher loads.
2J SPEED RESTRICTED TO 40MPH
This category is applicable to “Municipal vehicles”. “Municipal vehicles” means a motor vehicle or
trailer limited at all times to use by a local authority, or a person acting in pursuance of a contract
with a local authority, for road cleansing, road watering or the collection and disposal of refuse,
night soil or the contents of cesspools, or the purposes of the enactments relating to weights and
measures or the sale of food and drugs:
OR “Multi-stop local collection and delivery vehicles” being a motor vehicle or trailer used for multi-
stop collection and delivery services to be used only within a radius of 25 miles from the permanent
base at which it is normally kept.
Note: For these vehicles the tyre load index capacity rating must be increased by 15%, for example
a tyre used in single formation with a 143 load index is now increased from 5450kg maximum load
to 6267kg.
| [] | [] | [] | [] | train |
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07 Size and Type of Tyres
Table 2 Load capacity index table
Extract from ECE Reg 54: “Load index” Table amended to show axle loads
Load
Index
Single
Kg
Dual Kg
Load
Index
Single
Kg
Dual Kg
Load
Index
Single
Kg
Dual Kg
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
670
690
710
730
750
774
800
824
850
874
900
924
950
974
1000
1030
1060
1090
1120
1160
1200
1230
1260
1300
1340
1380
1420
1460
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
2000
2060
1340
1380
1420
1460
1500
1548
1600
1648
1700
1748
1800
1848
1900
1948
2000
2060
2120
2180
2240
2320
2400
2460
2520
2600
2680
2760
2840
2920
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4120
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
2120
2180
2240
2300
2360
2430
2500
2570
2640
2720
2800
2900
3000
3100
3200
3300
3400
3500
3600
3700
3800
3900
4000
4120
4240
4360
4480
4600
4720
4860
5000
5150
5300
5450
5600
5800
6000
6150
6300
6500
4240
4360
4480
4600
4720
4860
5000
5140
5280
5440
5600
5800
6000
6200
6400
6600
6800
7000
7200
7400
7600
7800
8000
8240
8480
8720
8960
9200
9440
9720
10000
10300
10600
10900
11200
11600
12000
12300
12600
13000
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
6700
6900
7100
7300
7500
7750
8000
8250
8500
8750
9000
9250
9500
9750
10000
10300
10600
10900
11200
11600
12000
12300
12600
13000
13400
13800
14200
14600
15000
15500
13400
13800
14200
14600
15000
15500
16000
16500
17000
17500
18000
18500
19000
19500
20000
20600
21200
21800
22400
23200
24000
24600
25200
26000
26800
27600
28400
29200
30000
31000
| [] | [] | [] | [] | train |
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07 Size and Type of Tyres
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07 Size and Type of Tyres
TABLE 4 MAX AXLE LOADS FOR “UNRESTRICTED” SPEED VEHICLES
Tyre load
Index
Trailers permitted to exceed 50mph (up to
60mph)
Motor vehicles permitted to exceed 60mph (up
to 70mph)
Speed Symbol F (-
15%)
Speed Symbol G (-
5%)
Speed Symbol J (-
7%)
Speed Symbol K (-
3%)
Single Kg
Dual Kg
Single Kg
Dual Kg
Single Kg
Dual Kg
Single Kg
Dual Kg
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
570
590
610
630
640
660
680
700
730
750
770
790
810
830
850
880
910
930
960
990
1020
1050
1080
1110
1140
1180
1210
1250
1280
1320
1360
1410
1450
1490
1530
1580
1620
1660
1700
1760
1810
1860
1910
1960
2010
2070
2130
2190
1140
1180
1210
1250
1280
1320
1360
1410
1450
1490
1530
1580
1620
1660
1700
1760
1810
1860
1910
1980
2040
2100
2150
2210
2280
2350
2420
2490
2550
2640
2720
2810
2890
2980
3060
3150
3230
3320
3400
3510
3610
3710
3810
3910
4020
4140
4250
4370
640
660
680
700
720
740
760
790
810
830
860
880
910
930
950
980
1010
1040
1070
1110
1140
1170
1200
1240
1280
1320
1350
1390
1430
1480
1520
1570
1620
1670
1710
1760
1810
1860
1900
1960
2020
2080
2130
2190
2250
2310
2380
2450
1280
1320
1350
1390
1430
1480
1520
1570
1620
1670
1710
1760
1810
1860
1900
1960
2020
2080
2130
2210
2280
2340
2400
2470
2550
2630
2700
2780
2850
2950
3040
3140
3230
3330
3420
3520
3610
3710
3800
3920
4030
4150
4260
4370
4580
4620
4750
4890
630
650
660
680
700
720
750
770
800
820
840
860
890
910
930
960
990
1020
1050
1080
1120
1150
1180
1210
1250
1290
1330
1360
1400
1450
1490
1540
1590
1630
1680
1730
1770
1820
1860
1920
1980
2030
2090
2140
2200
2260
2330
2390
1250
1290
1330
1360
1400
1440
1490
1540
1590
1630
1680
1720
1770
1820
1860
1920
1980
2030
2090
2160
2240
2290
2350
2420
2500
2570
2650
2720
2790
2890
2980
3070
3170
3260
3350
3450
3540
3630
3720
3840
3950
4060
4170
4280
4390
4520
4650
4780
650
670
690
710
730
760
780
800
830
850
880
900
930
950
970
1000
1030
1060
1090
1130
1170
1200
1230
1270
1300
1340
1380
1420
1460
1510
1560
1610
1650
1700
1750
1800
1850
1900
1940
2000
2060
2120
2180
2240
2290
2360
2430
2500
1300
1340
1380
1420
1460
1510
1560
1600
1650
1700
1750
1800
1850
1890
1940
2000
2060
2120
2180
2250
2330
2390
2450
2530
2600
2680
2760
2840
2910
3010
3110
3210
3300
3400
3500
3590
3690
3790
3880
4000
4120
4230
4350
4470
4580
4720
4850
4990
| [] | [] | [] | [] | train |
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07 Size and Type of Tyres
TABLE 4 (continued) MAX AXLE LOADS FOR “UNRESTRICTED” SPEED VEHICLES
Tyre load
Index
Trailers permitted to exceed 50mph (up to
60mph)
Motor vehicles permitted to exceed 60mph (up
to 70mph)
Speed Symbol F (-
15%)
Speed Symbol G (-
5%)
Speed Symbol J (-
7%)
Speed Symbol K (-
3%)
Single Kg
Dual Kg
Single Kg
Dual Kg
Single Kg
Dual Kg
Single Kg
Dual Kg
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
2250
2320
2380
2470
2550
2640
2720
2810
2890
2980
3060
3150
3230
3320
3400
3510
3610
3710
3810
3910
4020
4140
4250
4380
4510
4640
4760
4930
5100
5230
5360
5530
5700
5870
6040
6210
6380
6590
6800
7020
7230
7440
7650
7870
8080
8290
8500
4490
4630
4760
4930
5100
5270
5440
5610
5780
5950
6120
6290
6460
6630
6800
7010
7210
7420
7620
7820
8030
8270
8500
8760
9010
9270
9520
9860
10200
10460
10710
11050
11390
11730
12070
12140
12750
13180
13600
14030
14450
14880
15300
15730
16150
16580
17000
2510
2590
2660
2760
2850
2950
3040
3140
3230
3330
3420
3520
3610
3710
3800
3920
4030
4150
4260
4370
4490
4620
4750
4900
5040
5180
5320
5510
5700
5850
5990
6180
6370
6560
6750
6940
7130
7370
7600
7840
8080
8320
8550
8790
9030
9270
9500
5020
5170
5320
5510
5700
5890
6080
6270
6460
6650
6840
7030
7220
7410
7600
7830
8060
8290
8520
8740
8970
9240
9500
9790
10070
10360
10640
11020
11400
11690
11970
12350
12730
13110
13490
13870
14250
14730
15200
15680
16150
16630
17100
17580
18050
18530
19000
2460
2530
2610
2700
2790
2890
2980
3070
3170
3260
3350
3450
3540
3630
3720
3840
3950
4060
4170
4280
4390
4520
4650
4790
4930
5070
5210
5400
5580
5720
5860
6050
6240
6420
6610
6790
6980
7210
7440
7680
7910
8140
8370
8610
8840
9070
9300
4910
5060
5210
5400
5580
5770
5960
6140
6330
6510
6700
6890
7070
7260
7440
7670
7890
8110
8340
8560
8780
9040
9300
9580
9860
10140
10420
10790
11160
11440
11720
12090
12470
12840
13210
13580
13950
14420
14880
15350
15810
16280
16740
17210
17670
18140
18600
2570
2640
2720
2820
2910
3010
3110
3210
3300
3400
3500
3590
3690
3790
3880
4000
4120
4230
4350
4470
4580
4720
4850
5000
5150
5290
5420
5630
5820
5970
6120
6310
6500
6700
6890
7090
7280
7520
7760
8010
8250
8490
8730
8980
9220
9460
9700
5130
5280
5440
5626
5820
6020
6210
6410
6600
6790
6990
7180
7380
7570
7760
8000
8230
8460
8700
8930
9160
9430
9700
10000
10290
10580
10870
11260
11640
11940
12230
12610
13000
13390
13780
14170
14550
15040
15520
16010
16490
16980
17460
17950
18430
18920
19400
| [] | [] | [] | [] | train |
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07 Size and Type of Tyres
Deficiency
Deficiency
Category
1
A tyre:
a. (i)
of which the nominal size, ply rating, load index or speed
Major
rating of any tyre is below that appropriate for the plated
axle weight.
(ii) of which the nominal size, ply rating, load index or speed
Dangerous
rating of any tyre is below that appropriate for the plated
axle weight and is loaded at least 10% in excess of the tyre
load index/ply rating.
b.
which has a tyre use marking inappropriate for the type of
Major
axle or vehicle to which it is fitted.
c.
of a different nominal size to another on the same axle.
Major
d.
of a different structure to another on the same axle.
Dangerous*
e.
on a steerable axle which is not of the same structure as
Dangerous*
any other tyre on any steerable axle.
f.
on a driven axle which is not of the same structure as any
Dangerous*
other tyre on any driven axle.
2
On a two axle motor vehicle fitted with single tyres on both
Dangerous*
axles a combination of tyres with structures which are not
shown as acceptable in the table.
| [] | [] | [] | [] | train |
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Heavy Goods Vehicle Inspection Manual
08 Condition of Tyres
Application
The examination for tyre condition applies to all tyres fitted to vehicles and trailers apart from
spare tyres.
The check for tyre age markings does not apply to:
• category T tractors.
• motor vehicles and trailers below 3501kgs DGVW.
• motor vehicles and trailers with a first use date of forty years and over and used for non-
commercial purposes.
Trailer tyres require age markings, but the age of the tyre is not applicable.
Procedure and standards
Lifting of the tread rubber is a deficiency.
If a portion of the tread material is partially severed so that it is likely to fly off and cause
danger for other road users, it is a deficiency.
The following criteria should be used when assessing a cut in a tyre:
1. Any ply or cord that can be seen without touching the tyre would be a deficiency
under 1c.
2. If by folding back rubber or opening a cut with a blunt instrument, so as not to cause
further damage, exposed ply or cord can be seen irrespective of the size of the cut this
would be a deficiency under 1c.
3. If a cut which is more than 25mm or 10% of the section width whichever is the
greater, is opened with a blunt instrument and cords can be felt but not seen this
would be a deficiency under 1a.
Before failing a cut as listed in 3 above, you must ensure that it is definitely the cords that are
felt and not a foreign object.
When checking bulges care must be taken to distinguish between bulges caused by
separation or partial failure of the structure and the bulges which are due to normal manufacturing
undulations in the tyre or due to a satisfactory repair. A bulge due to a repair will be solid, feeling
firm to hand pressure and will not deflect as would a bulge associated with casing separation.
Recapped tyres may show unbonded surplus rubber at the tyre shoulder which may give the
appearance of tread separation, this is not a deficiency.
When checking any tyre that appears to have been recut, it must be determined whether it
has been recut to the manufacturers recut tread pattern. It is often difficult to identify tyres
which have been skilfully recut, but extra care should be taken to check for exposure of the ply
or cord at the bottom of the grooves.
Recut tyres can only be fitted to motor vehicles with an unladen weight of 2540kg or more and
to trailers with an unladen weight of more than 1020kg.
The original tread pattern means:
• On a re-treaded tyre the tread pattern immediately after the tyre was retreaded.
• On a recut tyre the manufacturer’s recut tread pattern.
• On a partly recut tyre, the part which has been recut the manufacturer’s recut tread
pattern, on the other part the tread pattern when new.
• On any other tyre the tread pattern of the tyre when new.
| [] | [] | [] | [] | train |
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08 Condition of Tyres
Fig (5)
In this case the lateral grooves are the same depth as the circumferential groove and are included
in the ¾ measurement.
The breadth of the tread is ‘T’.
The ¾ of ‘T’ measurement can be taken over ‘T’ as in figure 1 to 4.
Fig (6)
This tyre only has lateral grooving
The band of acceptable tread pattern includes the plain portion which existed when the tyre was
new. The remaining tread area should contain grooves to the depth of 1 mm.
If any tread wear indicator is level with corresponding tread, measure tread depth before
deciding if the tread is below the acceptable limit.
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08 Condition of Tyres
Tyre Age Markings
All tyres must be marked with the date of manufacture, this is represented by a four-digit code.
The first and second digits represent the week of manufacture, the third and fourth digits
represent the year.
For tyres manufactured before 01 January 2000, the date may be indicated by a three-digit code.
The first and second digits represent the week of manufacture, the third digit represents the year,
these will be in-excess of 10 years old.
The date code is only required to be marked on one sidewall and can usually be found at the end
of the DOT (Department of Transportation) marking on original manufactured tyres.
Retread or recapped tyres may be marked with two date codes, the original manufacture date,
and the date of remanufacture, the most recent date must be used when assessing tyre age.
Tyres not displaying a date code would normally be a deficiency. However, date codes are only
required to be marked on one side of the tyre so it may not be possible to see the date code on
some twin wheel fitments. Under these circumstances you should assume the date code is
present and the tyre age is acceptable.
If the date code shows the tyre age to be over 10 years old this will be a deficiency:
Example: Date of Vehicle examination 01 February 2021 which is week 06 (0621).
• A tyre marked 0611 will pass as it is not more than 10-years old.
• A tyre marked with the date code 0511 (or older) will be a deficiency as it is more than 10-
years old.
When assessing tyre age, front steered axles are those deemed to be forward of the chassis
midpoint and directly controlled by the vehicle steering system.
Presenters should be advised if any tyres fitted are between 9 and 10 years of age.
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hgv_manual | 48 | 49 | 3,198 | 510 |
Heavy Goods Vehicle Inspection Manual
09 Sideguards, Rear Under-Run Devices & Bumper Bars
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01/04/2025
Application
SIDEGUARDS (or Lateral Protection Device)
Motor Vehicles first used from 1 April 1984 with a design gross weight exceeding 3,500kg
and where the distance between the centres of any two consecutive axles exceeds 3m;
Trailers manufactured from 1 May 1983 with an unladen weight exceeding 1,020kg and
where the distance between the centres of any two consecutive axles exceeds 3m; or in the
case of a semi-trailer, where the distance between the centre of the kingpin position and the
centre of the foremost axle exceeds 4.5m.
Semi-Trailers manufactured before 1 May 1983 which have a gross weight exceeding 26,000kg
and which form part of an articulated vehicle with a gross train weight exceeding 32,520kg and
where the distance between the centre of the kingpin and the centre of the foremost axle exceeds
4.5m. Where more than one kingpin is fitted, it is the distance from the rearmost position which is
taken into account.
Exempted vehicles/trailers first used before 1st April 2025
• Articulated Tractor units.
• Category T vehicles.
• A vehicle or trailer constructed so that it can be unloaded by part of the vehicle being tipped
sideways or rearwards.
• A vehicle or trailer designed solely for use in connection with street cleaning, the
collection/disposal of refuse or the contents of gullies/cesspools. (Skip carrying vehicles are
classed as refuse vehicles and as such are exempt).
• A vehicle or trailer with specialised design characteristics (see interpretation of terms
section)
• A trailer specially designed and constructed, and not merely adapted, to carry round timber,
beams or girders, being items of exceptional length.
• A vehicle or trailer specially designed and constructed, and not merely adapted, to carry
other vehicles loaded onto it from the front or rear (Vehicles with a standard horizontal body
fitted with a "beaver tail" are not exempt).
• A trailer with a load platform which is not more than 750mm from the ground throughout that
part of its length under which a sideguard would have to be fitted.
• A semi-trailer incorporating a sliding bogie.
• A rigid motor vehicle or trailer designed for and constructed for the special purpose of
carrying long (but not exceptionally long) timbers from an off-road location in a forest.
To fulfil this definition the vehicle must meet the following criteria:
a. It must be of skeletal construction.
b. It must have a minimum of two upright side supports (side bolsters) fitted to each side of
the vehicle/trailer.
c. It must not be fitted with a load platform, other than chassis rails, cross bearers and the
minimum amount of flooring necessary to protect wiring or brake line components. It is
permissible for the vehicle to be fitted with the following:
Loading equipment i.e. a Hiab crane or similar device.
Cross bearers that do not have upright side supports.
This list is not exhaustive but covers the vehicles likely to be encountered within the testing
scheme.
| [] | [] | [] | [] | train |
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09 Sideguards, Rear Under-Run Devices & Bumper Bars
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REAR UNDER-RUN DEVICES
Rear under-run devices are applicable for motor vehicles with a gross design weight exceeding
3,500kg and first used from 1 April 1984, and trailers manufactured from 1 May 1983 with an
unladen weight exceeding 1,020kg
Exempted vehicles:
• Articulated Tractor units.
• Category T vehicles.
• A vehicle or trailer fitted at the rear with apparatus specially designed for spreading material on
a road.
• A vehicle or trailer so constructed that it can be unloaded by part of the vehicle being tipped
rearwards.
• A vehicle or trailer specially designed and constructed, and not merely adapted, to carry other
vehicles loaded onto it from the rear (Vehicles with a standard horizontal body fitted with a
“beaver tail” are not exempt.)
• A trailer specially designed and constructed, and not merely adapted, to carry round timber,
beams or girders, being items of exceptional length.
• A vehicle or trailer with specialised design characteristics (see interpretation of terms
section).
• A vehicle or trailer fitted with a tail lift so constructed that a lift platform, with a minimum length
of 1m, forms part of the floor of the vehicle.
• A vehicle specially designed, and not merely adapted, for the carriage and mixing of concrete.
• A vehicle fitted at the rear with specially designed apparatus where the fitment of under-run
would interfere with its operation.
This list is not exhaustive but covers the vehicles likely to be encountered within the testing
scheme.
BUMPER BARS
This inspection applies to all vehicles and trailers except category T vehicles.
| [] | [] | [] | [] | train |
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09 Sideguards, Rear Under-Run Devices & Bumper Bars
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Procedure and standards
SIDEGUARDS (or Lateral Protection Device) definition
An area is required to be protected between the front and rear wheels (or landing leg) as well as
the ground and vehicle/trailer body/platform designed to help prevent pedestrians, cyclists and
motorcyclists falling under the sides of the vehicle and being caught under the wheels.
A sideguard can be made up of a whole panel (including body panels), separate rails, or several
different components.
The sideguard “run” describes the sideguard area running front to rear.
Sideguards fitted to vehicles/trailers that do not require them will only be checked for deficiencies:
• (b) Security.
• (d) Sharp edges and/or projections.
• (h) Increasing overall width.
Sideguard (Lateral Protection Device) Dimensions
• Motor Vehicles
The front edge of the guard must not be more than 300mm from the tyre on the front
wheel (or second wheel if two front axles) and the guard must extend to within 300mm of
the tyre on the first rear axle.
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• Semi-Trailers
The front edge of the guard can be up to 250mm behind the centre line of the landing legs,
but never more than 3m behind the centre of the king pin (in its rearmost position) and the
guard must extend to within 300mm of the tyre on the first rear axle.
• Full Drawbar Trailers
The front edge of the guard must not be more than 500mm from the tyre on the front
wheel and the guard must extend to within 300mm of the tyre on the rear wheel.
• Centre Drawbar trailers (first used from 1st April 2025)
The front edge of the guard must extend no further forward than the front of the bodywork, (if any),
or the chassis where the drawbar connects and must not affect normal manoeuvrability of the
trailer.
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Minimum Height to Top Edge
The upper edge of a sideguard shall not be more than 350mm below that part of the structure of the
vehicle/trailer, cut or contacted by a vertical plane tangential to the outer surface of the tyres,
excluding any bulging close to the ground, except in the following cases.
The tangential (vertical) plane should be taken as a line from the outermost edge of the rear tyre(s)
excluding any tyre bulge due to the weight of the vehicle.
Minimum height to bottom edge
The minimum height from the ground to the bottom edge of the sideguard area is 550mm in all
cases where the vehicle is unladen. For semi-trailers, this is where the load platform is horizontal.
Lateral Projection
The guard must not project beyond the
outside edge of the vehicle, and it must not
be more than 150mm inside the outermost
plane of the vehicle/trailer (Maximum width).
The last 250mm of the sideguard, at the rear,
must be no more than 30mm from the outer
edge of the outermost rear tyre (excluding
any tyre bulge).
For vehicles with two rear axles where the rearmost axle has a narrower track, the sideguard
criteria must comply with the track width of the widest rear axle.
Where the tangential plane cuts the structure
of the vehicle at more than 1.3m above the
ground, then the upper edge of the sideguard
shall not be less than 950mm above the
ground.
Where the tangential plane does not cut the
structure of the vehicle, the upper edge shall be
level with the surface of the load carrying
platform,
or
950mm
from
the
ground,
whichever is the less.
| [
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205,
726
] | [
185,
231,
361
] | train |
hgv_manual | 54 | 55 | 2,548 | 409 |
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Vehicle/trailer body
If the sides of the vehicle/trailer are so designed and/or equipped, that by virtue of their shape and
characteristics the component parts together meet the requirements for the sideguard area, they
may be regarded as replacing the sideguards.
Where a vehicle/trailer’s body meets the dimensional requirements for sideguards these will be
deemed to be met, however where only part of the body meets the requirements, side guards
must be fitted in the remaining appropriate areas.
Vehicles/trailers which have shortened bodies to facilitate the fitting of plant equipment usually
have a large gap between the back of the cab and the body. There may therefore be a
considerable length of sideguard area not covered by the body. In these cases, the height of the
guard covered by the body is the normal 350mm max below the structure, but the height of the
guard in the area not covered by the body must be no lower than the body floor or 950mm
whichever is the lowest and may require more than 1 rail.
Sideguard Rail Dimensions
The front edge (or turn in) of the guard
must have a continuous vertical surface
extending back along the run:
(N2/O3 vehicles/trailers) minimum
50mm.
(N3/O4 vehicle/trailers) minimum
100mm.
The turn in (towards vehicle chassis)
For both ranges of vehicles/trailers is
minimum 100mm.
The continuous vertical rail (or turn in) may not be required if the front edge of the sideguard is
within 100mm of a permanent structure of the vehicle/trailer (cab/wheel arch). On occasions a
single rail may fulfil this requirement, and it will be sufficient that the forward face only covers the
depth of the rail.
Sideguard Construction
The sideguard:
• should be as continuous as possible and the outermost surface smooth, essentially rigid
and either flat or horizontally corrugated
• can be split into horizontal rails, as shown in the diagram above, the distance between them
must not be more than 300mm.
• can have parts that may be detachable for access but must be securely fixed when the
vehicle/trailer is in use.
• in some cases, may not be continuous; adjacent parts can overlap provided that the
overlapping edge faces rearwards or downwards; or a gap of not more than 25mm
measured longitudinally may be left, provided that the rearward part does not protrude
outboard of the forward part.
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hgv_manual | 55 | 56 | 1,534 | 238 |
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Sideguard Material
There is no legislation regarding the materials used for sideguards although there are regulations
covering strength and deflection of these components. None of these are subject to test.
Protrusions
Protrusions (on the sideguard area outer faces) such as rivets or bolt heads are acceptable
provided that they do not exceed 10mm and are suitably domed.
External corners and edges
Must not expose any sharp edge. Missing end caps are not a deficiency, but where this exposes a
sharp edge on an external corner this is a deficiency.
Components in the Sideguard Area
In general, the regulations do not allow for the sideguard run to be broken, if components such as
fuel tanks and air reservoirs intrude, the components should be sited such that they do not
interfere with the sideguard run. However, components may be incorporated if, by virtue of their
shape and characteristics, they conform in all respects to the sideguard requirements.
Protrusions from components not within the side guard area do not need to conform to the
standards.
Any Blind Spot Information System device(s) (RADAR or Camera) fitted within any gaps between
the horizontal rails that make up the sideguard area are permitted.
Note: Any component(s) that make up the sideguard area will be defined as sideguard for the
purposes of deficiency 2.
| [] | [] | [] | [] | train |
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Vehicles/Trailers equipped with cranes and/or stabiliser legs
It is not practicable to fit sideguards in the area of the crane and its controls. When assessing
such vehicles/trailers you need to take account of the following;
• Vehicles/trailers fitted with an extendible device or leg to provide stability during loading, and
equipped with loading devices and controls, which makes it impracticable to fully comply with
the sideguard legislation, will be deemed compliant provided sideguards are in place to the
fullest extent practicable. All vehicles/trailers must be presented for statutory test with any
such devices in the stowed and secured position.
• Vehicles/trailers with access and a working platform adjacent to, and necessary for, the
operation of a loading device, shall be regarded as a load carrying platform for sideguard
compliance forward of the extendable device or leg.
Chassis Mounted Cranes
Where cranes are fitted across the
chassis the extendible legs are
normally stowed and operate through
the sideguard run.
The sideguard rail(s) are required
to come within 130mm of the leg
at each side, thus allowing
working room.
The diagram is only to illustrate the dimensions allowed between the stabiliser leg and a
sideguard; it is not the intention that the stabiliser leg should be moved to this position during the
inspection
Type Approved Sideguards
If the presenter claims that the vehicle or trailer is fitted with type approved sideguards which
comply with the requirements of the EC directive, the presenter should be asked to provide
documentary evidence. Although the standards are to accept sideguards made to the directive
but not necessarily approved it may assist in identifying those vehicles/trailers which are known
to be approved, these are:
Trailer Make
Model
Hellbender
EUT, KIP, KIS, TSA, MUL, CONC.
Magyar
All models type approved.
Vehicle Make
Model
Mercedes-Benz
Atego
Sideguards can be manufactured & tested to any of the following standards:
The Road Vehicles (Construction and Use) Regulations 1986 as amended. Directive 89/297/EEC
or the technical requirements of the Directive 89/297/EEC.
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] | [
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At
least
950mm
Ladders encroaching
into the sideguard area
must comply with the
side guard regulations
(not applicable to fluid
tankers)
Sideguards must be no more than 150mm in from the outermost plane of
the vehicle (maximum width). The last 250mm of the guard at the rear must
be no more than 30mm from the tangential plane of the rear tyres.
At
least
950mm
Sideguards must be no more than 150mm in from the outermost plane of
the vehicle (maximum width). The last 250mm of the guard at the rear must
be no more than 30mm from the tangential plane of the rear tyres.
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959
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i.
with more than 550mm height from the ground to the lowest edge of
the guard. (vehicle unladen or semi-trailer load platform horizontal).
Major
3
Rear Under-Run Device:
a.
not fitted to a vehicle/trailer where required.
Major
b. (i) insecure
Major
(ii) insecure to the extent that detachment is imminent.
Dangerous
c.
cracked, fractured, corroded or damaged so that its effectiveness is
reduced.
Dangerous*
d.
that has a jagged edge.
Major
e.
with more than 550mm ground clearance (unladen).
Major
f.
Which extends beyond the outer edge of the outermost rear tyre (see
note in procedure and standards).
Major
g.
with the outer end of the device more than 100mm inboard of the outer
edge of the outermost rear tyre (or more than 300mm inboard where a
demountable body is fitted)
Major
h.
Extends beyond the outermost width of the vehicle/trailer which is fitted
with a tail lift.
Major
i.
incomplete
Major
| [] | [] | [] | [] | train |
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Heavy Goods Vehicle Inspection Manual
10 Spare Wheel & Carrier
Application
This inspection applies to all vehicles and trailers fitted with an external spare wheel or carrier.
Procedure and standards
Check the spare wheel and carrier are secure, free from damage, and are correctly positioned.
Deficiency
Deficiency
Category
1
A spare wheel carrier:
(i)
not in proper condition.
Minor
(ii) insecure, damaged or incorrectly positioned but not so that
Major
either is likely to fall from the vehicle.
(iii) so insecure, damaged or positioned that it is likely to fall from
Dangerous*
the vehicle.
2
A spare wheel:
(i)
insecure, damaged or incorrectly positioned but not so that it
Major
is likely to fall from the vehicle.
(ii) so insecure, damaged or positioned that it is likely to fall from
Dangerous*
the vehicle.
| [] | [] | [] | [] | train |
hgv_manual | 65 | 66 | 1,676 | 254 | 01/02/2021
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Heavy Goods Vehicle Inspection Manual
11 Vehicle to Trailer Coupling
Deficiency
Deficiency
Category
1
A drawing hitch, bar, hook, eye, ball or ball socket; or a
fifth wheel king pin and its mounting or a turntable which:
a.
(i)
is excessively worn.
Major
(ii) is excessively worn with obvious risk of detachment.
Dangerous*
b.
(i)
is seriously deformed or modified impairing its effectiveness
and or weakens the component (no trailer attached).
Major
(ii) is seriously deformed or modified impairing its effectiveness
and or weakens the component (trailer attached).
Dangerous*
c.
(i)
is cracked or fractured (no trailer attached).
Major
(ii) is cracked or fractured (trailer attached).
Dangerous*
d.
(i)
is insecure.
Major
(ii) is insecure to such an extent that detachment is likely.
Dangerous*
e.
has excessive movement between the vehicle and trailer.
Dangerous*
f.
has a turntable which has no clearance between mating
surfaces, i.e. evidence of contact between the surfaces.
Major
g.
has a missing, damaged, seized and or inadequate safety or
locking device or any coupling indicator inoperative.
Major
h.
has a coupling too weak.
Major
2
A Fifth Wheel Coupling with:
a.
(i)
insecurity between the fifth wheel and its mounting sub-frame
and or chassis.
Major
(ii) insecurity between the fifth wheel and its mounting sub-frame
and or chassis to such an extent that detachment is likely.
Dangerous*
b.
(i)
a mandatory bolt loose or missing.
Major
(ii) mandatory bolts loose or missing to such an extent that
detachment is likely.
Dangerous*
| [] | [] | [] | [] | train |
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11 Vehicle to Trailer Coupling
c.
(i)
jaws excessively, worn or out of adjustment.
Major
(ii) jaws so worn or out of adjustment that the trailer kingpin would
not be securely held.
Dangerous
d.
a safety locking device is missing or inoperative.
Major
e.
(i)
an articulating bracket or pivot excessively worn or insecure.
Major
(ii) an articulating bracket or pivot excessively worn or insecure to
such an extent that detachment is likely.
Dangerous*
f.
any crack in a load bearing member.
Major
g.
an operating member insecure or worn to such an extent the
coupling is unsafe.
Dangerous*
| [] | [] | [] | [] | train |
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Heavy Goods Vehicle Inspection Manual
12 Trailer Parking and Emergency Brakes and Air Line Connections
Application
Parking and Emergency Brakes
This inspection applies to all trailers.
Air Line Connections
This inspection applies to drawing vehicles first used from 1 April 1989 and all trailers.
Procedure and standards
Emergency Brake and Air Line Connections:
• Ensure that the air reservoirs on the drawing vehicle are fully charged.
• With the vehicle parking brake on and the trailer parking brake off, ask the driver to
disconnect the service (yellow) and emergency (red) brake lines.
• Check, on vehicles and trailers fitted with "C" type couplings, that the coupling in the
service (yellow) line - either fitted to the trailer or in the line itself - is fitted with an
operating adaptor which can open the self-sealing coupling in the connector from the
drawing vehicle.
• Check that the operating adaptor lifts the indicator on the test coupling by the correct
amount. The waisted portion (coloured section) of the indicator must be exposed, but no
more than this. This does not include additional couplings which may be used on trailers
such as extendable types.
• Check that any brake line on the drawing vehicle is not fitted with a manual shut-off tap.
Additional taps fitted to extendable trailers are not included in this inspection.
The driver must be instructed to reconnect all couplings before the vehicle is moved
When presented, the tractor unit must be compatible with the trailer and have a warning
lamp to indicate that trailer ABS is working (This may be a combined ABS/EBS warning light).
If presented with a compatible EBS tractor unit, if the red (emergency) line is dropped, the brakes
may not come on. To apply the brakes, disconnect the ISO 7638 electrical connection. Ensure
that the handbrake is applied on the tractor unit before disconnecting the red (emergency) line
and that safe working practices are followed.
Provided self-sealing couplings are used on the tractor couplings it does not matter whether
the air adaptor couplings are the conventional way or reversed.
Some park brake controls also deplete the air suspension systems when the red
(emergency) air line is removed, this is acceptable provided it does not drain the air brake
reservoir. If it does this is considered a deficiency under 5a of section 59.
| [] | [] | [] | [] | train |
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12 Trailer Parking and Emergency Brakes and Air Line Connections
Deficiency
Deficiency
Category
1
Trailer parking brake:
a.
does not operate on at least two wheels.
Dangerous
b.
cannot be securely set.
Dangerous
c. (i) mechanism worn.
Minor
(ii) mechanism insecure, cracked, excessively worn or badly
Major
corroded.
d.
when fully applied the mechanism is at the end of its working
Major
travel or it is fouling adjacent parts of the vehicle.
2
Trailer emergency brake not applied automatically when the
Dangerous
emergency brake line is disconnected.
3
Operating adaptor, to open self sealing coupling in
service line:
a.
not fitted in service line.
Major
b.
produces incorrect amount of lift.
Major
4
An airline fitted with a manual shut off tap.
Major
5
(i)
Tap or sealing valve insecure, inadequately mounted or
Minor
defective.
(ii)
Tap or sealing valve insecure, inadequately mounted or
Major
defective to such an extent the functionality is affected.
| [] | [] | [] | [] | train |
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Heavy Goods Vehicle Inspection Manual
13 Trailer Landing Legs
Application
This inspection applies to all trailers fitted with landing legs.
Procedure and standards
Check for security of landing legs and any of its component parts.
If any leg or part of a leg is missing it is not a deficiency.
Deficiency
Deficiency
Category
1
A landing leg or any component part so insecure that it is likely
Dangerous*
to fall from the vehicle.
| [] | [] | [] | [] | train |
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Heavy Goods Vehicle Inspection Manual
14 Spray Suppression, Wings and Wheel Arches
Application
Wings and Wheel Arches
This inspection applies to all vehicles and trailers.
Spray Suppression
This inspection applies to those vehicles shown below unless listed as exempt.
Motor Vehicles
Trailers
a. exceeding 12 tonnes design GVW and
first used from 1 April 1986.
a. exceeding 3.5 tonnes design GVW and
manufactured from 1 May 1985.
b. exceeding 16 tonnes design GVW with
2 or more axles, whenever
manufactured.
Spray Suppression Exempted Vehicles:
• Motor vehicle where the driving power of its engine is, or can by use of its controls be,
transmitted to all the wheels on at least one front axle and on at least one rear axle.
• Vehicles with a high ground clearance (400mm minimum).
• A vehicle specially designed and not merely adapted for the carriage and mixing of
concrete.
• A vehicle or trailer constructed so that it can be unloaded by part of the vehicle being
tipped sideways or rearwards.
• A vehicle or trailer designed solely for use in connection with street cleaning, the
collection/disposal of refuse or the contents of gullies/cesspools (skip carrying vehicles
are classed as refuse vehicles and as such are exempt).
• A trailer specially designed and constructed, not merely adapted, to carry round timber,
beams or girders being items of exceptional length.
• Category G and T vehicles.
• A rigid motor vehicle or trailer designed for and constructed for the special purpose of
carrying long (but not exceptionally long) timbers from an off road location in a forest.
To fulfil this definition the vehicle must meet the following criteria:
a. It must be of skeletal construction.
b. It must have a minimum of two upright side supports (sidebolsters) fitted to each
side of the vehicle.
c. It must not be fitted with a load platform, other than chassis rails, cross bearers and
the minimum amount of flooring necessary to protect wiring or brake line
components.
It is permissible for the vehicle to be fitted with the following:
Loading equipment e.g. a Hiab crane or similar device.
Cross bearers that do not have upright side supports.
Tractor units drawing exempt trailers are not themselves exempt.
For Vehicles of a specialised design or use characteristics see interpretation of terms
section. This list is not exhaustive but covers the vehicles likely to be encountered within the testing
scheme.
| [] | [] | [] | [] | train |
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14 Spray Suppression, Wings and Wheel Arches
Procedure and standards
Wings and Wheel Arches
Road wheels must have associated with them equipment or part of the body which, as far as is
practicable, catches mud or water thrown up by the wheels as they rotate. Check that the wing
covers the whole width of the tyre especially where wide “Super Single” tyres are fitted to the front
axle.
A trailer used for or in connection with the carriage of round timber does not require the
fitment of wings.
With regard to the requirements for wings and wheel arches, a vehicle may be passed
without wings when a semi-trailer/body/ container is carried which fulfils the requirements of a
wing i.e. a vehicle presented for annual test towing a trailer and the wing tops are not fitted on the
vehicle due to the trailer being very close to the tyres. This is not a deficiency for wings or spray
suppression providing the rotation of the wheels does not permit mud or water to be thrown
directly on the road surface.
Mudflaps
If a mudflap is an extension to a wing or similar fitting, a missing or damaged mud flap is not a
deficiency, unless the vehicle is required to have one to comply with spray suppression
requirements.
Where a mudflap is fitted in place of a wing, i.e. it serves the purpose of a wing (as on some
semi-trailers) it must be treated as a wing and be securely fixed to prevent excessive movement.
Spray Suppression
The test on spray suppression includes only a basic visual check for general compliance
and it will normally not be necessary to take measurements.
Tractor units and Skeletal Vehicles/ Trailers must be fitted with complete wings to fulfil the
spray suppression requirements.
Lifting axles are not exempt from the requirements and are therefore treated as a normal axle.
Vehicles/Trailers with Demountable Bodies
1. These are not exempt from the requirements. In some cases it will therefore be
necessary for the body to be in place since the mudwing or valance is often attached.
2. Some demountable bodies can be unloaded by tipping, using a conventional ram
attached to the vehicle. These are classed as tippers and are therefore exempt from the
spray suppression requirements.
The 200mm flap height can be increased to 300mm for:
• any vehicle or trailer equipped with road friendly suspension.
• where a manufacturer has deemed it technically appropriate as permitted in 91/226/EEC
and regulation EU 109/2011.
• the rear most flap height only, for trailers claimed to be used on Ro-Ro ferry operations.
• any axle where the radial dimension to the lower edge of the valancing, or wheel guard, is
not greater than the radius of the tyre.
| [] | [] | [] | [] | train |
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14 Spray Suppression, Wings and Wheel Arches
Deliberate modifications for attachment points for rope hooks are not acceptable and should
be considered as incomplete.
The width of the flap should cover the full breadth of the tyre(s).
Vehicles/trailers first used from 1 April 2000 must have spray suppression that covers the whole
width of the tyres. It is acceptable for vehicles/trailers before 1 April 2000 that the spray
suppression will only cover the tyre tread breadth.
Earlier Mercedes Actros model ranges had gaps between the spray suppression flap top edge
and the mud wing bottom edge (the edges were not parallel with each other); these do not comply
with the spray suppression requirements and should be considered a defect. The later models do
comply because the gap is at the same level as the mud wing thus containing the spray thrown up
by the rotation of the wheel (see below).
On trailers where all the wheels steer, it may appear to be incompatible to fit spray
suppression, these vehicles are not exempt but spray suppression only needs fitting as far as it is
practicable.
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14 Spray Suppression, Wings and Wheel Arches
Conventional Mudwing Types of Wheel Guards
Single Axle Arrangements or Multi-axle arrangements where distance between wheels is greater
than 300mm.
The lower edge of the outer valance shall not exceed 1.5 x tyre radius on steerable wheels or
1.25 x tyre radius on non-steerable wheels at points A, B and C.
Wheel Flaps
Wheel flaps must be fitted behind each wheel and should cover the full breadth of the tyre(s) and
be mounted to the wing without gaps that would permit the exit of spray.
Suppression material must be fitted to:
a. the forward face of the flap and
b. to the forward face of that part of the wing (guard) if it reaches below a line 100mm above a
line projected from the wheel centre line.
Wheel Guards
Where the wheel guard consists of several components there should be no gaps between or
within individual parts when assembled that will permit the exit of spray when the vehicle is in
motion.
| [
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] | [
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] | [
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] | train |
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14 Spray Suppression, Wings and Wheel Arches
Conventional Mudwing Types of Wheel Guards
Multi-axle arrangements where distance between wheels is 300mm or less
The lower edge of the outer valance shall not exceed 1.5 x tyre radius on steerable wheels or
1.25 x tyre radius on non-steerable wheels at points A,B and C as in the single axle diagram.
Wheel Flaps
Wheel flaps should cover the full breadth of the tyre(s) and be mounted to the wing without gaps
that would permit the exit of spray.
Wheel flaps are required behind each wheel where the distance between tyres on a group of
multiple axles is 250mm or more. Up to 290mm can be accepted where it is clear that the limit of
249mm is exceeded only by tyre wear.
Where the distance between tyres on a group of axles is less than 250mm, wheel flaps are only
required on the rearmost axle of each group.
Suppression material must be fitted to:
• The forward face of the flap and
• The forward face of that part of the wing (guard) if it reaches below a line 100mm above a
line projected from the wheel centre line.
Wheel Guards
Where the wheel guard consists of several components there should be no gaps between or
within individual parts when assembled that will permit the exit of spray when the vehicle is in
motion.
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14 Spray Suppression, Wings and Wheel Arches
Single or Multi-axle arrangements using Half Wing and Valances.
‘B’
VALENCE
45mm MIN.
VALENCE
45mm MIN.
20°
‘A’
‘C’
100mm MIN.
300mm
MAX.
200mm
FRONT
MAX.
Fig.4
The lower edge of the outer valance shall not exceed 1.5 x tyre radius on steerable wheels or
1.25 x tyre radius on non-steerable wheels at points A, B and C.
Wheel Flaps
Wheel flaps must be fitted behind each wheel and should cover the full breadth of the tyre(s) and
be mounted to the wing without gaps that would permit the exit of spray.
Where the distance between tyres on a group of axles is less than 250mm, wheel flaps are only
required on the rearmost axle of each group. Up to 290mm can be accepted if it is clear that the
limit of 249mm is exceeded only by tyre wear.
Suppression material must be fitted to:
• The forward face of the flap and
• to the forward face of that part of the wing (guard) if it reaches below a line 100mm above
a line projected from the wheel centre line.
Wheel Guards
Where the wheel guard consists of several components there should be no gaps between or
within individual parts when assembled that will permit the exit of spray when the vehicle is in
motion.
Note that in the case of steerable wheels the 20 Deg. angle is increased to 30 Deg.
The breadth of the wing valance at points A and C must be at least 45mm as must be the body
valance depth at point B.
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14 Spray Suppression, Wings and Wheel Arches
Flap and Valance System for Non-Steered Axles
The valance should cover the area extending from the underside of the body to at least a line
formed by the tangent to the top of the tyres and between the outer edge of the wheel flap, with
which it should form a seal and the vertical plane formed by the tangent at the front of the tyre. An
outer valance must be fitted over each wheel.
The whole inner face of the outer valance, the depth of which should not be less than 100mm,
must be fitted with a suppression material.
Wheel Flaps
Wheel flaps should extend to the underside of the vehicle structure. The whole of the forward
facing part of the wheel flap should be fitted with a suppression material or device. There should
be no gaps that would permit the exit of spray.
Suppression material must be fitted to:
• the forward face of the flap and
• to the forward face of that part of the wing (guard) if it reaches below a line 100mm above
a line projected from the wheel centre line.
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14 Spray Suppression, Wings and Wheel Arches
Deficiency
Deficiency
Category
1
A Wing or Wheel Arch:
a.
(i)
missing or so badly corroded or distorted to stop it acting as
Major
an adequate shield or, in the case of a mud flap fitted as a
wing, it is not restrained or constructed to stop wind lift.
(ii) so badly corroded or distorted or so insecure that it can fall off Major
or rub on the tyre.
b.
that has sharp edges that are likely to cause injury
Major
c.
which is rubbing on a tyre.
Major
d.
which does not cover the whole width of a tyre when the
Major
wheel is in the straight ahead position.
2
Spray Suppression:
a.
insecure to such an extent it is likely to drop off.
Major
b.
not fitted where required.
Major
c.
incomplete or seriously defective.
Major
d.
dimensions do not comply with requirements.
Major
e.
with a wheel flap not restrained or stiff enough to stop
Major
excessive movement or wind lift in normal use.
f.
with more than 25% of the minimum required wheel flap or
Major
spray suppression material area clogged with mud or debris.
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15 Cab Security
Application
This inspection applies to all vehicles.
Procedure and standards
All means of securing the cab are to be inspected where practical.
Movement which is designed into mountings should not be confused with excessive wear.
Cab security inspection applies to the primary and secondary locking devices for tilt cabs.
The inspection does not cover air leaks from cab air suspension unless it affects the brakes.
This would be a deficiency within the appropriate brake section.
Deficiency
Deficiency
Category
1
A Cab:
a. (i)
insecure but not affecting the stability of the vehicle.
Major
(ii)
with any insecurity that is likely to affect the stability of the
Dangerous*
vehicle.
b. (i)
retention and/or locking device on a tilt cab missing or
Major
defective.
(ii) retention and/or locking device on a tilt cab missing and or
Dangerous
defective to such an extent that it seriously affects road safety.
c.
obviously not located squarely on chassis and which obviously Major
affects safe control of the vehicle.
d.
(i)
with excessive corrosion or damage to a load bearing member Major
which seriously reduces its strength within 30cm of the cab
mountings.
(ii) with excessive corrosion or damage to a load bearing member Dangerous
which seriously reduces its strength within 30cm of the cab
mountings and stability is obviously affected.
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16 Cab Doors
Application
This application applies to all motor vehicles.
Procedure and standards
Only one operational door is required. On security vehicles this door may be fitted so that it
does not open directly into the cab. Other doors which have deliberately been made inoperative
should be considered part of the cab and not a door. A door with one handle missing should not
be refused, if the door can be opened from inside using the remaining handle.
Deficiency
Deficiency
Category
1
A Door which:
a.
is missing.
Major
b.
cannot be opened.
Major
c.
(i)
has a sliding action and it will not remain closed or is likely to
Major
fly open inadvertently.
(ii) has a hinged action and it will not remain closed or is likely to
Dangerous
fly open inadvertently.
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17 Cab Floor and Steps
Application
This inspection applies to all motor vehicles.
Procedure and standards
Examine the cab floor, internal wheel arches and cab steps for condition and security.
Deficiency
Deficiency
Category
1
A cab floor or internal wheel arch which:
(i)
is badly deteriorated or insecure.
Major
(ii)
is so badly deteriorated or insecure it is likely to impair the
Dangerous*
driver’s control of the vehicle or is likely to cause injury.
2
Any step or step ring:
(i)
insecure.
Minor
(ii)
so insecure or in such a condition it is likely to cause injury.
Major
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18 Seats
Application
This inspection applies to all vehicles driver and passenger seats.
Procedure and standards
When checking the driver’s seat adjustment, it is not necessary to check that the seat can be
secured in all possible positions.
In the case of electrically adjusted seats, it is not necessary to check any ‘memory position’
function.
Deficiency
Deficiency
Category
1
A driver’s seat:
a. (i)
structure defective.
Major
(ii) so insecure or in such a condition that it could cause the driver
Dangerous*
to lose control of the vehicle.
b.
fore and aft adjustment mechanism not functioning as
Major
intended.
2
A passenger seat insecure or a backrest that cannot be
Major
secured in the upright position.
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19 Security of Body, Containers and Crane Support Legs
Application
Security of Body
This inspection applies to all vehicles and trailers fitted with a body.
Security of Containers
This inspection applies to all vehicles and trailers constructed or adapted to carry removable
shipping containers, whether a container is mounted or not (a dual-purpose flatbed trailer from
which all twistlocks have been removed is not subject to this inspection).
Security of Crane Support Legs
This inspection applies to all vehicles and trailers fitted with supporting legs for loading cranes.
This inspection only applies where retaining devices were originally fitted. A suitable
alternative retaining device is acceptable provided the support leg is adequately secured.
Procedure and standards
Security of Body
The inspection covers:
• all fixings (e.g. brackets) securing the body to the chassis or to a sub-frame or supporting
members.
• fastenings e.g. securing bolts, rivets or welds for the fixings.
• structural (stressed) panels.
Defective fastenings do not necessarily mean that the body is insecure. The whole structure
must be assessed, and deficiencies will only be justified where sufficient bolts, rivets and welds
etc. are loose or defective to allow the body to move enough to cause a hazard for other road
users.
Some designs of body mounting allow a limited amount of flexing between the body and
chassis. This must not be confused with insecurity. On body mountings with tie-bars the securing
nut on the tie-bar is correctly secured with a relatively low torque setting and this should not be
mistaken for looseness.
Coach bolt failure due to corrosion may not be obvious, as the failed section may be in a
position where it cannot be seen. Care should be taken to check that there is no sign of an
abnormal movement of the structure which would indicate coach bolt failure.
Security of Containers
A secondary locking device is something that stops the primary fastening device coming
open accidentally when the vehicle is in motion. To be effective it must give enough resistance to
light hand pressure to remain closed.
Support Bolsters and Structures
Presenters should be asked to set any moveable supports or bolsters to a deployed position
wherever possible prior to the commencement of the test to assist inspection. The presenter
should reset them after the test within British legal length requirements before leaving the test
site.
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19 Security of Body, Containers and Crane Support Legs
Deficiency
Deficiency
Category
1
Body:
a.
excessively displaced relative to the chassis.
Major
b. (i) insecure.
Major
(ii) insecure with stability affected.
Dangerous
2
A load bearing member so cracked, corroded or damaged that the
body is:
(i)
seriously weakened.
Major
(ii)
seriously weakened and vehicle/trailer stability is impaired.
Dangerous
3
A container fastening device:
a.
missing when another of a matched pair is present.
Major
b.
likely to become detached.
Major
c.
incomplete.
Major
d.
seized.
Major
e.
not fitted with an effective secondary locking device.
Major
f.
in such a condition that a container is unlikely to be secured by it.
Dangerous*
4
A support bolster or structure:
a.
insecure, cracked, corroded or damaged such that a container is
unlikely to be supported and secured by it.
Dangerous*
b.
not fitted with locking pins or other securing method incorporating an
effective secondary locking device.
Major
5
A crane support leg:
a.
insecure.
Dangerous*
b.
retaining device missing, insecure or in a condition that it would not
adequately retain the leg.
Dangerous
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20 Condition of Body
Application
This inspection applies to all vehicles and trailers.
Procedure and standards
Check for defective items, which would make the vehicle dangerous to other road users or
pedestrians. The cumulative effect of any defects found must be considered or their influence on
other items. Superficial damage which does not affect the strength of a component, or which does
not pose a danger to other road users is not a deficiency.
Check for any insecurity of glass panels or sharp-edged glass on vehicles such as mobile shops.
Deficiency
Deficiency
Category
1
Any headboard, rave, cross or longitudinal member, hinge
or retaining device, tipping gear, glass panel or any part
of the body designed to carry or contain the load
(including the floor and main support pillars):
a.
(i)
insecure, fractured or cracked, distorted, worn, corroded,
damaged or modified, to such an extent it is likely to cause
injury.
Major
(ii) insecure, fractured or cracked, distorted, worn, corroded,
damaged or modified to such an extent the vehicle is
obviously dangerous to other road users, passengers or
pedestrians.
Dangerous
b.
(i)
with an inappropriate modification of the bodywork.
Major
(ii) with an unsafe modification of the bodywork which has
seriously weakened the component.
Dangerous
2
(i)
a leak from the load carrying compartment which poses a risk
to other road users.
Major
(ii)
a leak from the load carrying compartment which poses a very
serious risk to other road users.
Dangerous
3
A wind deflector or other accessory so obviously insecure that
it is likely to become detached.
Dangerous*
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22 Mirrors and Indirect Vision Devices
Category T vehicles are required to meet the requirements of a vehicle from 1 April 1985
Application
This inspection applies to all vehicles. The number and type of mirrors and or indirect vision devices
(excluding periscopes) which have to be fitted are shown below
DATE OF FIRST USE
REQUIREMENTS
Before 1 April 1985
An exterior mirror on the offside and either an interior mirror
(unless this would not give a view to the rear) or an exterior
mirror on the nearside
From 1 April 1985
A main exterior mirror on both the offside and nearside
From 1 October 1988 with
DGVW greater than 12000 kg
A close proximity mirror on the nearside in addition to those
shown above
From 1 October 1988
articulated vehicles with DGVW
greater than 12000 kg
A wide-angle mirror on the nearside in addition to those
shown above
From 1 January 2000 with a
DGVW exceeding 3500kg
A main exterior mirror on both the offside and the nearside
A wide-angle mirror on the passenger side.
A close proximity mirror on the passenger side.
From the 26 January 2007 with
a DGVW exceeding 7500 kg
A main exterior mirror on both the offside and the nearside.
A wide-angle mirror on both the offside and the nearside
A close proximity mirror on the passenger side.
A front mirror
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22 Mirrors and Indirect Vision Devices
Procedure and standards
Vehicles registered from 26 January 2007 but before 26 January 2008 in excess of 7500kg
may not have a front mirror, these vehicles should be treated as if derogated and therefore pass
and advise for this aspect of the inspection.
Any vehicle registered from 26 January 2008 in excess of 7500kg must have a front mirror,
provided it can be fitted more than 2m from the ground.
“Indirect vision devices " means devices to observe the traffic area adjacent to the vehicle
which cannot be observed by direct vision. These can be conventional mirrors, camera-monitors
or other devices (but not a periscope) able to present information about the indirect field of vision
to the driver.
For vehicles up to 7500kg if the close-proximity mirror cannot be fitted at least 2m from the
ground. The vehicle does not require either the wide angle or close-proximity mirrors.
Known makes and models over 3500kg that do not require wide angle or close-proximity
mirrors are:
• Iveco Daily
• Johnston Sweepers 5000 series
• Mercedes Chassis Cab Vario with two-wheel drive and all Sprinters
• Mitsubushi Fuso Canter
• Nissan Cabstar
• Isuzu N Series this is any Isuzu up to 7500kg
• Renault Mascott and Maxity
• Volkswagen LT and Crafter
There are a minority of vehicles which can achieve the view to the front without a front
mirror, if you are in any doubt about the necessity for a front mirror contact TaSS Swansea.
The retro fitting of mirrors from 1 January 2000 does not include the front mirror.
For the purpose of this inspection on a left hand drive vehicle the nearside is at the right and
the offside at the left.
Close proximity and front mirrors must be at least 2m from the ground. If a vehicle is fitted with
a low mounted cab so that the mirror cannot be fitted at this height it is exempt from the
requirement to fit a close proximity and front mirror. Some Mercedes Unimogs fall into this
category or the category of not being a forward control vehicle the U300, U400, U500 & U3000,
U4000, U5000, Zetro 1833A and Zetro 2733A are exempt the front mirror but the U20 is not
exempt and requires a front mirror.
Deficiency 2 will not apply to cameras replacing front and or close proximity mirrors fitted less
than 2 metres from the ground where the camera is hidden within the body contour.
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22 Mirrors and Indirect Vision Devices
Deficiency
Deficiency
Category
1
Not fitted with the correct number or type(s) of mirror, or other
Major
indirect vision device.
2
Part of any required close proximity, front mirror or camera for
Major
an indirect visual device is fitted less than 2 metres from the
ground.
3
(i) A required mirror or indirect vision device with minor damage
Minor
that does not obviously interfere with the view to the rear,
nearside or front where required of anyone sitting in the driving
seats.
(ii) A required mirror or indirect vision device in such a condition
Major
that anyone sitting in the driving seat cannot see clearly
towards the rear or nearside or front where required.
4
A mirror/indirect vision device or its mounting bracket insecure
Major
or structurally deteriorated.
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23 Glass and View of the Road
Application
This inspection applies to all vehicles.
Procedure and standards
Zone "A" is 350mm wide, in the swept area of the screen
and centred on the centre of the steering wheel.
Zone "B" is the remainder of the swept area.
Zone "C" is the remainder of the screen outside the sweep of the wipers.
Windscreen
Examiners should have regard for the three separate "zones" when assessing damage or
discolouration. A greater amount of damage or discolouration could be accepted in zone "C" than
in zone "B". Likewise, a greater amount can be accepted in zone "B" than in zone "A" where
relatively minor damage may be a deficiency.
When assessing damage, light surface scratches are not to be considered as damage.
However, an area of concentrated scratches such as those caused by prolonged use of a
defective wiper blade which materially affects view to the front, or the sides is to be considered a
deficiency.
Repaired windscreens must be inspected to the same criteria as original unrepaired
screens. Repairs must be judged as to whether they materially affect view to the front or the
sides.
“Swept area” means the area swept by the wipers in their normal operation and does not include
any additional area of the screen covered by the wipers to reach the parked position or which the
original manufacturer has designed as opaque.
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23 Glass and View of the Road
Check the view of the road from the driver’s seat. The view must not be obstructed by any
changes to the original design such as the addition of stickers, pennants, cab decorations, stone
guards, dash mounted tables or other items, which materially affect view to the front or the sides.
On many vehicles, the original design will place things like instrument panel clusters
inside the field of view. Intrusions such as this which are an original design features can be
ignored, as can damage, obstructions or unofficial stickers which are hidden by that feature.
Many commercial vehicles have very large screens and have windscreen wipers which
cover an area that have no practical use. For the purposes of the annual test, the area of the
screen above a horizontal line taken from the driver’s eye position, assessed from the driving seat
looking forward in a comfortable upright driving position, can be ignored other than the area
through which the driver is required to view any mirror (front mirrors on HGVs are not required to
be viewed through the area swept by the wipers). It is not necessary to speculate on the effects of
tall or short drivers.
Official stickers and acceptable features (see examples below) are permitted to encroach
into the field of vision if this is necessary to comply with other regulations. These will be
considered a deficiency only where they seriously restrict the drivers view to the front or the
sides.
Examples of acceptable features which may intrude into the swept area of the wipers provided
they do not seriously restrict the drivers view to the front or the sides are:
• Vehicle distance or lane indicator systems
• Operator licence
• Automatic windscreen wiper detectors
• Fresnel lens
• Split windscreens
• Wipers which park adjacent to a central pillar
• Driver monitoring systems
• Driver’s aids such as blinds and their mountings
• Toll payment tags/stickers
• Vehicle anti-theft scheme stickers/security passes
• Monitors for indirect vision devices
Examples of features which may intrude into the swept area of the wipers provided they do not
materially affect view to the front or the sides are:
• No smoking signs
• Maximum height signs
• Maintenance information stickers
• Other non-mandatory signs or stickers
• Dash mounted tables, laptops/tablets/mobile phones/satellite navigation which is not
original equipment
• Dash mount monitors/control systems
Note: It is important to remember the monitors mounted on a dash will be used for different
purposes such as monitoring/controlling of refrigeration systems which will be assessed as
whether they materially affect view whereas monitors for safety features such as blind spot
systems for indirect vision requirements will be assessed as to whether they seriously affect view.
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23 Glass and View of the Road
Deficiency
Deficiency
Category
1
A Windscreen:
a.
(i) with an obstruction, damage or discolouration which materially
affects view to the front or the sides through the area of
windscreen not swept by the wipers (zone C).
Minor
(ii) with an obstruction, damage or discolouration which materially
affects view to the front or the sides through the area of
windscreen swept by the wipers.
Major
b.
(i) with a crack in the windscreen outside of the area swept by
the wipers (zone C).
Minor
(ii) with a crack passing through the swept area which renders the
screen insecure, or which materially affects view to the front or
the sides through the area of windscreen swept by the wipers.
Major
c.
with any crack where there is noticeable displacement of the
surfaces on either side which has an adverse effect on the
condition and operation of the windscreen wipers.
Major
d.
with damage which exposes the inner layer of a laminated
screen.
Major
2
A windscreen or window:
a.
so insecure that it is likely to fall out or damaged to the extent
that it presents a danger to occupants or to other road users.
Dangerous*
b.
with damage or obstruction, which impairs the driver’s view of
a mandatory mirror.
Major
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25 Windscreen Wipers and Washers
Application
This inspection applies to all vehicles except those with an opening windscreen or where an
adequate view can be obtained by some other means.
Procedure and standards
Wipers must be able to clear an adequate area of the screen to give the driver a view of the
road to the front and in front of both sides of the vehicle.
Washers must provide enough water to enable the wipers to clear the screen effectively.
Frozen washers are to be considered a deficiency.
There is no requirement to check that wipers self-park.
Wipers working on an intermittent speed only are not acceptable and will be a deficiency
under 2b.
Check switches that control windscreen wipers and or washers are fitted and operational.
Deficiency
Deficiency
Category
1
Switch(es) controlling windscreen wipers and/or washers
Minor
missing or defective.
2
Wipers:
a.
do not move over an adequate area.
Major
b.
do not work continually when switched on.
Major
c.
a blade missing, insecure or so deteriorated that it cannot clear
Major
the screen effectively.
3
Windscreen washers not working or not providing sufficient
Major
fluid to clear the windscreen.
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26 Speedometer/Tachograph
Application
This inspection applies to all vehicles.
A vehicle must have a tachograph fitted unless the presenter claims that it is exempt from the
tachograph regulations. Exempt vehicles may have either a tachograph or a speedometer fitted.
Procedure and standards
The check of tachograph seals is by visual assessment only.
1C tachographs must be installed to all vehicles requiring a tachograph registered from June
15th, 2019.
All vehicles
A tachograph exemption form must be completed for all vehicles deemed as tachograph exempt,
unless the vehicle technical record shows the vehicle is exempt or it is declared on the application
form.
If the time clock is inoperative this is a deficiency under 1b(ii) (for the tachograph only not the
speedometer).
For vehicles fitted with a tachograph
If the tachograph head cannot be opened or if the calibration plaque does not match the
vehicle to which it is fitted it should be treated as if the plaque and any relevant seals were not
there.
If the vehicle identification on the calibration plaque does not correspond to the vehicle it is fitted
to, the vehicle should be refused under 2a. Should the identification refer to the registration mark,
the technical record must be checked to ensure it was not a previous registration for the same
vehicle. If no vehicle identification is displayed this is not a deficiency, there is no requirement to
display the registration mark on the calibration plaque.
For vehicles required to be fitted with a tachograph
The tachograph head must only be opened with the steering wheel in the straight-ahead
position and with the engine switched off.
Installation/calibration plaques expire after 6 years for analogue, 2 years for digital.
It is acceptable for the plaque to contain additional information (e.g. Registration Number, tyre
pressures etc.). The plaque is designed to be tamper proof and should show signs of damage if it
has been tampered with. The 2-year check is not part of this inspection for analogue tachographs
only. However, if the examiner notices this plaque is not displayed the presenter must be
advised.
Check DIL switch covers and seals for presence and condition and that they are the correct type.
It will be sufficient to check that they have an approved marking. It is not necessary to identify the
sealer.
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26 Speedometer/Tachograph
For vehicles not required to be fitted with a tachograph where a tachograph is used as
a speedometer
If a tachograph is used in place of a speedometer (even if the vehicle is tachograph exempt) it is
only required to be marked in kilometres per hour, although it may be dual marked in miles per
hour also.
Only where the tachograph is marked in KPH alone, will you be required to check the
installation/calibration plaque for presence and condition, and the date of calibration is clearly
visible.
There is no requirement for a re-calibration of these systems after 6 years provided that the
system has been initially calibrated and sealed, and that the calibration plaque and necessary
seals remain intact.
If a speed limiter is NOT required, or the speed limiter does not receive the speed signal from
the tachograph head, it is only necessary to check the seals inside the tachograph head. There is
no requirement for the gearbox sender unit to be sealed. The vehicle technical record will show if
a vehicle is speed limiter exempt.
Vehicles fitted with Modular Tachographs
There are presently two types of modular tachograph using encrypted sender units. They are
VDO Keinzel 1324 and Stoneridge Electronics (formerly TVI) and are easily identified as they are
shaped like a car radio.
Vehicles fitted with Digital and or Modular Tachograph systems have received type approval
that permits the use of a 4 wire data transmission cable instead of an armoured cable provided it
is used to connect an encrypted sender unit to the tachograph. When used in this arrangement
the approval also does not require the cable end connections to be sealed. However, the sender
unit itself is still required to be sealed to the gearbox.
Where a printout from a digital tachograph cannot be obtained initially (because of a
jammed or depleted roll) the presenter should be given the opportunity to rectify this before
leaving the test site and the use of PRS would not be appropriate if the defect is rectified.
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26 Speedometer/Tachograph
Identification of Encrypted Sender Units
These appear similar to other sender units and can be positively identified by the cream/beige
colour of the sender unit 4 pin bayonet connector. This colour is the same whether the sender
unit is the rotating type or a proximity type. It should be noted that when the cable is connected
that only a small part of the cream/beige coloured connector is visible.
For the VDO Keinzel 1324 there is an exception to the above colour code when the vehicle
is fitted with a TELMA retarder, the socket housing will be red.
If a vehicle is fitted with more than one tachograph and a speed limiter, the speed limiter
should operate off all tachographs.
Plastic sleeve seals are
acceptable but will require
an embossed identification,
(see example to left).
Tachograph plaques are required to be tamperproof; this is not a deficiency at annual test if
they are not tamperproof.
| [
"iVBORw0KGgoAAAANSUhEUgAAAoAAAAHgCAIAAAC6s0uzAAAACXBIWXMAAA7EAAAOxAGVKw4bAArwAElEQVR4nGy9Z3AcSZbnWXYfztbW9nZ2tme7prurq0tTggRJkAShtdYAoQES1FprFlks0aWrWIKahBaJ1FpGZkZGaq0zoQGKEq2m52zn9j7f38NZvLazM3sWFkgRGeHi/d7f/bnjJebuuG9SGVUwQZnOLVV7VdoQw0RslpSbSzktKTsz4zDNO5hZiyaiErlFwwm9JqSUpU36x05u2c6uuO2wuFEb0WvDOg0sZNBGTPqgXuN... | [
"a26c38474be7540fb190d436b1a477384941fdf5e15467d3ed513273f4f4aae5",
"47d45bfe5098cbe00ed8cc15c8d4a960dab7907ced12b8b4bf7275fb6b834c8c"
] | [
640,
2214
] | [
480,
1832
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26 Speedometer/Tachograph
Deficiency
Deficiency
Category
1
A speedometer or tachograph (where required):
a.
not fitted.
Major
b. (i)
incomplete or dial glass broken without affecting the
operation.
Minor
(ii) incomplete, clearly inoperative, or with dial glass missing or
broken and affecting the operation.
Major
c.
cannot be illuminated.
Major
2
For all vehicles fitted with a tachograph:
a.
tachograph installation/calibration plaque missing or damaged
(where required).
Major
b.
DIL switch cover missing, broken or damaged through
interference.
Major
3
For vehicles required to be fitted with a tachograph:
a.
tachograph scale not marked in kilometres per hour. (There is
no requirement for tachographs to be marked in m.p.h.).
Major
b.
tachograph manufacturer’s serial number/data plaque missing
or not showing an “e” marking.
Major
c.
tachograph installation/calibration plaque out of date.
Major
d.
where a digital tachograph is fitted the size of drive axle road
tyres do not comply with calibration plaque.
Major
e.
“K” factor plaque missing.
Major
f.
seal missing, broken or where a clearly “non mandatory” seal
has been fitted in place of an “official” seal.
Major
g.
unable to obtain a printout from a digital tachograph.
Major
h.
a digital tachograph that displays a ‘K’ factor reading different
to that shown on the calibration plaque (there is no
allowance/tolerance as with analogue type tachographs).
Major
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27 Horn
Application
This inspection applies to all vehicles.
Procedure and standards
Vehicles first used from 1 August 1973 must have a horn that produces a continuous or uniform
sound.
If vehicles are fitted with more than one horn only one has to work.
If air horns are connected to the braking system of a vehicle the presenter should be made
aware of the possible dangers as well as advising of any leaks from the air horns (there is no
requirement to check if air horn operation depletes the braking system).
If more than one horn control is fitted at least one must operate the horn.
Deficiency
Deficiency
Category
1
Horn control:
a.
missing.
Major
b.
cannot be reached easily from the driving seat.
Major
c.
insecure.
Major
2
Horn:
a.
does not work.
Major
b.
is not loud enough to be heard by other road users.
Major
c.
sound not continuous or uniform.
Major
d.
insecure.
Major
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28 Driving Controls
Application
This inspection applies to all vehicles.
Procedure and standards
From the driver’s seat operate driving controls, except those for brakes and steering which are
checked under other items, to see that they function correctly and are complete.
Examples of driving controls which need to be inspected are:
1. Gear control.
2. Accelerator pedal.
3. Clutch pedal.
The list is not exhaustive.
An air leak from a gear valve is not a deficiency.
An accelerator pedal anti slip provision missing or worn smooth is not a deficiency.
Check the designated engine stop control for presence and operation.
Deficiency
Deficiency
Category
1
A driving control:
a.
(i)
insecure.
Major
(ii) insecure and safe operation of the vehicle obviously
Dangerous
affected.
b.
(i)
incomplete.
Major
(ii) incomplete and safe operation of the vehicle obviously
Dangerous
affected.
c.
(i) fractured, cracked or excessively corroded.
Major
(ii) fractured, cracked or excessively corroded and safe
Dangerous
operation of the vehicle obviously affected.
d.
(i)
obstructed or impeded in its travel.
Major
(ii) obstructed or impeded in its travel and safe operation of the
Dangerous
vehicle obviously affected.
e.
(i) obviously not functioning correctly.
Major
(ii) obviously not functioning correctly and safe operation of the
Dangerous
vehicle obviously affected.
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28 Driving Controls
f.
with the presence of rubbish or other items likely to interfere
with the proper control of the vehicle.
Dangerous
g.
(i) clutch pedal anti-slip provision missing, loose, incomplete or
ineffective.
Major
(ii) clutch pedal anti-slip provision missing, loose, incomplete or
ineffective and safe operation of the vehicle obviously
affected.
Dangerous
2
Engine stop control missing or inoperative.
Major
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30 Steering Control
Application
This inspection applies to all vehicles.
Procedure and standards
Cracks in the plastic covering do not necessarily mean that a spoke is fractured.
This inspection does not apply to drivers’ aid steering wheel knobs.
Unless specified by the manufacturer vehicles fitted with power steering must be checked with
the engine running.
“Free Play” must not be confused with movement caused by the compression of steering joints
etc. This operation should be carried out with light finger pressure to distinguish the feel of the
steering wheel when it meets a resistance.
Certain types of steering column might show some movement not due to excessive wear,
e.g. those fitted with universal joints or flexible couplings.
Free play at the steering rim in excess of 1/30 of the steering wheel diameter for a rack and
pinion mechanism is considered a deficiency. For other types of mechanism free play in excess
of 1/5 of the wheel’s diameter is considered a deficiency. The acceptable free play for a range of
wheels is shown below.
Rack and Pinion Steering
Wheel
Diameter
Conventional
With Steering wheel ahead of
the rack with a number of joints
Other types of steering
380mm (15”)
13mm (0.5”)
48mm (1.9”)
76mm (3”)
455mm (18”)
16mm (0.6”)
57mm (2.3”)
90mm (3.6”)
530mm (21”)
18mm (0.7”)
67mm (2.6”)
106mm (4.2”)
610mm (24”)
21mm (0.8”)
77mm (3.3”)
122mm (4.8”)
Check the steering column has no excessive end float, when applying an upward and downward
pressure to the steering wheel in line with the column.
Check the steering column has no excessive side play indicating a badly worn top bearing or
insecure top mounting bracket, by pulling and pushing the rim.
With the steered wheels in the straight-ahead position lightly rotate the steering wheel to the left
and right and note the amount of free play.
On vehicles that are equipped with a steering lock (anti-theft device) these should be
checked for functionality. It's acceptable for a steering lock to be inoperative if the vehicle has an
engine immobiliser, or a permanently installed immobilisation device which acts on either the
steering, brakes or the transmission.
Some electronic steering locks, generally on vehicles with keyless ignition systems, will only
activate when the driver’s door is opened or closed.
If it’s not practical to check if a steering lock is working, you should give the benefit of the doubt.
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30 Steering Control
e.
(i) locking mechanism not functioning correctly.
Major
(ii) locking mechanism not functioning correctly and affects safe
steering operation.
Dangerous
3
(i) Free play in system which is outside the prescribed limits.
Major
(ii) Free play in system which is outside the prescribed limits
obviously effecting safe control of the vehicle.
Dangerous
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33 Speed Limiter
Application
This inspection applies to all vehicles which are required to be fitted with a speed limiter.
Vehicles required to be fitted with a speed limiter are:
A. A vehicle first used from 1 January 1988 with:
• a design gross weight of more than 12000kg and
• a maximum speed capability exceeding 56 mph (90 km/h), if a speed limiter were not
fitted
Must be fitted with a speed limiter set at a maximum stabilised speed of 56 mph (90 km/h).
B. A vehicle first used from 1 August 1992 until 30 September 2001 with:
• with a design gross weight of more than 7500kg and not exceeding 12000kg and
• a maximum speed capability exceeding 60mph (96.5km/h) if a speed limiter were not
fitted
Must be fitted with a speed limiter set at a maximum of 60 mph (96.5 km/h).
C. A vehicle first used from 1 October 2001 until 31 December 2004 with a Euro 3 Diesel or Gas
engine (See note) with:
• a design gross weight of more than 3500kg and not exceeding 7500kg and
• a maximum speed capability exceeding 90km/h if a speed limiter were not fitted
Must be fitted with a speed limiter set at a maximum stabilised speed of 56 mph (90 km/h)
from 1 January 2007.
D. A vehicle first used from 1 October 2001 until 31 December 2004 with:
• a design gross weight of more than 7500kg and not exceeding 12000kg and
• a maximum speed capability exceeding 90 km/h if a speed limiter were not fitted
Must have a speed limiter set at 56 mph (90 km/h).
E. A vehicle first used from 1 January 2005 with:
• a maximum design gross weight of more than 3500kg and not exceeding 7500kg
• a maximum speed capability exceeding 90km/h if a speed limiter were not fitted
Must be fitted with a speed limiter set at a maximum stabilised speed of 90 km/h from 1
January 2008.
F. A vehicle first used from 1 January 2005 with:
• a design gross weight of more than 7500kg and not exceeding 12000kg and
• a maximum speed capability exceeding 90km/h if a speed limiter were not fitted
Must be fitted with a speed limiter set at a maximum stabilised speed of 90 km/h.
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33 Speed Limiter
Procedure and standards
Some vehicles first used from 1 October 2001 until 31 December 2004 may have been
approved to Directive 70/220/EC or fitted with Euro 2 engines. These vehicles are exempt from
the speed limiter fitting requirements for Group C. Where exemption is claimed at time of test this
should be accompanied by an operator’s declaration of exemption and where necessary
supported by manufacturer’s confirmation of emission test standard, unless the vehicle is marked
speed limiter exempt on the technical record. All the following listed vehicles have already been
confirmed by their manufacturers as being exempt and no further proof is required for these
vehicles:
Any Petrol engine or petrol engine converted to run on LPG
Citroen Relay 2.0 litre and 2.2 litre HDi engines
DAF 45, 7.5 ton vehicles (all) except DAF 45 marked as LF. (LF is marked on the N/S of the
radiator grill.)
Fiat Ducato with 2.0 litre engines (engine code RHV).
Ford Transit (all).
Isuzu models NPR, NQR, and NKR with T, V, W, X or 1(one) as the 10th VIN character.
Iveco Cargo all, except vehicles with engine code F4AE---.
Iveco Daily all, except vehicles with engine code F1CE---, 8140.43B, 8140.43N and 8140.43S
with a PIC code ‘G.’ (the PIC code is applicable to the 8140.43S only, the PIC code can be found
on the ID plate on the shut panel for the bonnet identified by the third character.)
LDV (all).
Mitsubishi Canter with ‘R’ as the 12th VIN character.
Nissan Interstar all, except vehicles with engine code ZD3-A202, G9U-A754 & G9U-A724.
Nissan Primastar All models.
Peugeot Boxer 2.0 litre and 2.2 litre HDi engines.
Renault Master all, except vehicles with engine code ZD3-A202, G9U-A754 & G9U-A724.
Renault Trafic All models.
Vauxhall/Opel Movano with E, F, G, J, K, L, M, N, P, T or W as the 7th VIN character.
Vauxhall/Opel Vivaro (all).
Volkswagen (all except 2.5lt/2.8lt 109bhp/158bhp engine codes AVR & AUH respectively).
Other vehicles which are exempted by regulations are:
Vehicles owned or used by the Secretary of State for Defence and used for naval, military or air
force purposes. If the vehicle is being used the driver must be under the direct orders of a
member of the armed forces of the Crown.
Vehicles being used for fire brigade (in England and Wales fire and rescue authority), ambulance
and police purposes.
Vehicles which are an emergency tactical response vehicle operated by or on behalf of Her
Majesty’s Prison Service and used primarily for the purpose of transporting people or equipment
(or both) to restore order within Her Majesty’s prisons or immigration detention centres.
If for any other reason the vehicle presenter claims a valid exemption that is different from
the technical record, form DVSA 74 V2 must be completed.
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33 Speed Limiter
When checking a speed limiter plate is securely fitted in the driver’s compartment it is
acceptable for the plate to be fitted in the driver’s door jamb. If fitted on a window and facing
outward the details must be able to be read by a person of average height.
The character and composition of the plate and size of the lettering are not important provided
the details are legible.
It is acceptable for the limiter to be wired through the “ignition” switch but any other device
which would allow disconnection of the speed limiter whilst driving is unacceptable.
Clear DIL switch covers are acceptable at the time of test, although once again they are no
longer acceptable under the Tachograph approved scheme and centres should no longer fit them.
The inspection of speed limiters is only for the parts which are visible without dismantling.
Plastic speed limiter seals are acceptable if they are properly marked with a sealer
identification.
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33 Speed Limiter
Deficiency
Deficiency
Category
1
Speed Limiter Plate:
a.
missing.
Major
b.
insecure.
Minor
c.
not in a conspicuous position.
Minor
d.
not clearly and indelibly marked with the set speed.
Major
2
Set Speed marked on Speed Limiter Plate greater than:
a.
90km/h (56 mph) for a vehicle described in Application section
Minor
Groups A, C, D, E & F.
b.
96.5 km/h (60 mph) for a vehicle described in Application
Minor
section Group B.
3
Speed Limiter:
a.
not fitted or obviously inoperative.
Major
b.
insecure.
Major
c.
actuating rods/cables disconnected or damaged so that the
Major
operation is obviously affected.
d.
wiring disconnected or can easily be disconnected by
Major
unauthorised means.
e.
tamperproof device missing or defective or showing obvious
Major
signs of interference.
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34 Pressure/Vacuum Warning and Build Up
Application
This inspection applies to all vehicles, except those with an unladen weight of less than 3050kg
where the vacuum reservoir is coupled direct to the engine induction manifold. These vehicles do
not require a pressure/vacuum warning device (if it is not possible to determine the unladen
weight of a vehicle, the presenter should be given the opportunity to produce some evidence of
the unladen weight before failing the vehicle).
Procedure and Standards
Vehicles used from 1 April 1983 can be fitted with either a visual warning device or an audible
warning device. If both are fitted only one need work. Vehicles first used before 1 April 1983
must be fitted with a visual warning device. If an audible warning device is also fitted this is
considered to be an addition to the mandatory requirement.
A number of vehicles, among them Mercedes 515, 609, 612, 614, 709 and Iveco Daily models
were approved without a warning device and should not be failed for a warning device not fitted.
If there is no reservoir in a vacuum system a warning device is not required.
Deplete the air or vacuum system by applying the footbrake, when the warning device operates
there must be four further assisted applications.
If the vehicle has full power hydraulic brakes, gauges are not normally fitted and there are no
appreciable sounds when the brakes are applied. To check for compliance, use the procedure
shown in IM 71.
Fully deplete the system and run the engine at just below governed speed and note the time for
the warning device to show minimum effective working condition.
If gauges are not marked, take 3 bar (45 psi) for air systems and 25 to 30cm (10 to 12 Inches)
for vacuum systems as indicating minimum effective working condition.
The time to reach minimum effective working pressure should normally be within 3 minutes
for pressure systems and 1 minute for vacuum systems. With Type Approved vehicles designed
to draw a trailer, whether one is attached or not, a build-up time of 6 minutes is acceptable. If,
however, the time recorded for the vehicle is appreciable longer than expected from that type of
vehicle, this should be taken to indicate undue wear or a defect in the equipment.
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37 Service Brake Pedal
Application
This examination applies to all vehicles.
Procedure and Standards
Power operated braking systems where the foot valve is fully open before the pedal is fully
depressed do not require any reserve travel.
Some category T vehicles may have a split service brake assembly, which is capable of operating
each side of the vehicles brakes independently. The assembly must be locked together when
presented for test and where this is not the case this will be considered a deficiency (2d).
Deficiency
Deficiency
Category
1
Brake pedal:
a.
anti-slip provision missing, loose, incomplete or ineffective.
Major
b.
has excessive side play.
Major
c.
fouling other parts of the vehicle and is functionality affected.
Major
d.
insufficient reserve travel when fully depressed.
Major
2
Brake pedal or assembly:
a.
insecure, incomplete, fractured, cracked, or corroded and is
functionality affected.
Major
b.
pivot is tight in operation.
Major
c.
(i)
does not release correctly.
Minor
(ii) does not release correctly and functionality is affected.
Major
d.
capable of applying each side of the vehicles brakes
independently and the assembly is unlocked.
Dangerous
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38 Service Brake Operation
Application
This inspection applies to all vehicles and trailers.
Vehicles and trailers on which anti-lock brakes are mandatory
Type of Vehicle
Date
Motor vehicles with design GVW greater than
16000kg and authorised to tow a semi-trailer or a
centre axle drawbar trailer with total design axle
weights greater than 10000kg or a drawbar trailer
with design GVW greater than 10000kg. (an O4
trailer) See examples 1 and 2 below to determine
whether a motor vehicle needs antilock brakes
First used from 1 April 1992 and up to 30
April 2002
Motor vehicle with design GVW greater than 3500kg
First used from 1 May 2002
Semi-trailers and centre axle drawbar trailers with a
design total axle weight of more than 10000kg
Manufactured from 1 October 1991
Semi-trailers and centre axle drawbar trailers with a
design total axle weight of more than 10000kg and
which do not have a load sensing valve
Manufactured from 1 October 1982 to 30
September 1991
Semi-trailers and centre axle drawbar trailers with a
design total axle weight of more than 3500kg
Manufactured from 1 May 2002
Full drawbar trailers (turntable type) with a design
GVW of more than 10000kg
Manufactured from 1 October 1991
Full drawbar trailers (turntable type) with a design
GVW of more than 10000kg and which do not have
a load sensing valve
Manufactured from 1 October 1982 to 30
September 1991
Full drawbar trailers (turntable type) with a design
GVW of more than 3500kg
Manufactured from 1 May 2002
Anti-lock Brake exempt vehicles
A public works vehicle which has a maximum design GVW of 7500kg and which is specifically
designed for use and used solely for the purpose of street cleansing.
How to determine if a drawing vehicle first used from 1st April 1992 and before 1 May 2002
needs antilock brakes.
Example 1
Semi-Trailer
or
Rigid and Drawbar Trailer
DGVW 18000kg
| [
"iVBORw0KGgoAAAANSUhEUgAAAPkAAABGCAIAAACBsaVnAAAACXBIWXMAAA7EAAAOxAGVKw4bAAAOdElEQVR4nO2dLXcjOxKGAwwGDAkxMgoLDgoNHxhs5r8w1Mh4kc8Ju2DJgiX5BeFjvmjQsLBhl2Wf6Nmu1bg/7CR2OjOu9/TxaXdLckl6VSqVPnz2NAZubm6+FNwkEkdGMO1sFK6fn5+v12t+/uHh4T6ROCbm8/lisYBy43B9MplcXV3NZjPofp1IHBMXBVBuHK5Pp9PVagXR//2vf+SV1/Gu0OtQbhyuo9H/+uufyyW/nld... | [
"3cd90c80184fce1126a3fbf440ccd66871f6f4729997d02080ba47ee3530581c",
"2b523adbb9ed7effebf22cdc3800a28056f18d963f7d8a91288efe158618bf2a"
] | [
249,
302
] | [
70,
71
] | train |
hgv_manual | 114 | 115 | 3,113 | 532 | 01/02/2021
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38 Service Brake Operation
Procedure and Standards
The tow hitch should have a manufacturer’s identification plate showing the hitch capacity.
For some brake systems a small amount of creep may be due to elasticity in the brake
components.
For test purposes it will only be possible to check the static part of the warning light
sequence. Some systems require movement of the vehicle, but this is not part of the test.
If a trailer is submitted for test coupled to a motor vehicle which has no power supply for
the trailer anti-lock system, the test should be suspended on the grounds that the trailer has not
been accompanied by a suitable drawing vehicle. The presenter should be informed of this on
form VTG12.
If a trailer does not have a warning light, this is acceptable provided that the drawing vehicle
has a trailer warning light fitted in the cab. If neither the tractor nor trailer has a warning light and
there is a separate connector for the anti-lock system, the test should be suspended as described
above. If neither has a warning light and the trailer anti-lock is operated through the stop lamp
circuit the trailer should be refused under deficiency 5a.
Vehicles and trailers fitted with ABS are not required to have a LSV. However, if an LSV is
fitted and known to be a standard fitment this is a deficiency if it is removed or disconnected refer
to IM59.
There is no requirement to check the colour of Malfunction Indicator system warning lamps.
ABS, ABS/EBS and ABS/EBS/ESC requirements
ABS only vehicles
Vehicles fitted with ABS only must have a mandatory warning malfunction indicator lamp (MIL)
that illuminates when the system is energised (ignition or battery master switch on). It can be any
colour, though they are usually red, yellow or amber. It must go out after a short period or when
the engine is started but can then come back on and remain on until the vehicle speed exceeds
approximately 5 kph (3 mph). It is not necessary to move the vehicle to check the speed-
activated function provided the lamp does go off momentarily.
Trailers fitted with ABS must have either; a warning lamp (usually green and fitted on the trailer
headboard), or if this is not present then there must be a trailer ABS warning lamp in the motor
vehicle cab of any colour separate from the vehicle warning lamp. If trailer ABS warning lamps are
fitted to both vehicle and trailer both systems must work (on some trailers the trailer warning lamp
may be extinguished when the ISO7638 cable is fitted).
Other lamps of the same or different colours showing e.g. that trailers are not connected or are
not fitted with ABS may also be fitted to motor vehicles. These are not mandatory and are for
information purposes only. If these are illuminated it is not a deficiency. It is important to
establish that a lit warning lamp is actually showing an ABS defect and is not an ABS information
lamp. The Driver Handbook may be used to establish the function of a lamp.
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38 Service Brake Operation
ABS/EBS equipped vehicles
Vehicles fitted with ABS and EBS must have mandatory red and amber/yellow MILs fitted.
Drawing vehicles must be fitted with a separate amber/yellow MIL for the trailer, though one red
MIL may be shared between tractor and trailer. If separate tractor and trailer Red MILs are fitted,
they are both required to work.
The red MIL illuminates if there is a foundation brake fault or the prescribed minimum brake
performance cannot be met. The red MIL must illuminate with system initialisation though this
may not be clearly evident as in some cases the sequence is extremely fast and may be missed.
In this circumstance if modulator cycling can be heard it is acceptable to pass the vehicle. It may
be necessary to wait as much as 30 seconds before re-testing to allow the system to re-set. If a
red MIL stays lit or is flashing this is a deficiency.
The amber/yellow lamp illuminates if there is an electronic fault
The amber/yellow MILs must illuminate with system initialisation though this may not be clearly
evident as in some cases the sequence is extremely fast and may be missed. In this circumstance
if modulator cycling can be heard it is acceptable to pass the vehicle. It may be necessary to wait
as much as 30 seconds before re-testing to allow the system to re-set.
If the MIL stays lit this is a deficiency. If the MIL illuminates on system initialisation, then goes out
and then flashes this should be advised.
ABS/EBS/ESC equipped vehicles
Motor vehicles fitted with ESC must have a separate amber/yellow MIL fitted apart from those
used to signal EBS electronic faults. One lamp covers both the motor vehicle, and any trailer
fitted with ESC towed.
The ESC lamp will be illuminated when the system is switched off, when the system is operating
or if a fault is present. It is not required to light up on system energisation, but if it does this is
acceptable provided it then goes out after a short period or when the engine is started.
If the vehicle has a switch to manually disable the ESC function, it must not be possible for the
switch to be left in the “off” position and the ESC function must be automatically reinstated every
time the system is re-energised (ignition turned on.)
Electronic Stability Control Systems are commonly referred to as ESC, but may also be known as
ESP/RSC or some other acronym. The MIL for these systems may take various forms and a
vehicle should only be refused when the tester is certain that an illuminated lamp indicates an
ESC malfunction. This may require reference to the owner’s handbook if one is available.
| [] | [] | [] | [] | train |
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38 Service Brake Operation
Deficiency
Deficiency
Category
1
Air pressure or vacuum systems gauge reading drops
when pedal depressed indicating a leak in the system.
Major
2
Hydraulic systems (other than full power systems):
a.
pedal creeps down to the floor when depressed.
Major
b.
sponginess when pedal depressed.
Major
3
(i)
Servo unit defective or ineffective.
Major
(ii)
Pedal does not dip when engine started, indicating lack
of assistance for brake systems assisted by engine
vacuum.
Dangerous*
4
Full pressure hydraulic system pressure is not
maintained for 10 minutes when the brakes are off and
the engine is stopped.
Major
5
Any of the required ABS or ABS/EBS or ESC
warning lamps:
a.
are missing.
Major
b.
do not illuminate as required when ignition switched on.
Major
c.
indicate a fault.
Major
6
Vehicles and Trailers fitted with ABS or ABS/EBS or
ESC:
a.
a system component obviously missing or excessively
damaged.
Major
b.
system wiring excessively damaged.
Major
c. (i)
a system component with an inappropriate modification.
Major
(ii)
a system component with an unsafe modification which
has seriously weakened the component, does not
provide sufficient clearance to other vehicle parts or
renders the component inoperative.
Dangerous
d.
an ESC system switch insecure or faulty or which does
not allow automatic resetting of the ESC function to “on”
at system energisation.
Major
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38 Service Brake Operation
7
On vehicles and trailers both fitted with ISO 7638
(ABS/EBS) lead sockets an ISO 7638 connecting lead
not fitted or being used.
Major
8
A mandatory ABS system not fitted to a vehicle or trailer
where it is a mandatory requirement.
Major
| [] | [] | [] | [] | train |
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39 Hand Operated Brake Control Valves
Application
This examination applies to all hand operated control valves on vehicles which operate secondary
brakes, trailer brakes, spring brakes and lock actuators. It also applies to trailers fitted with hand
operated spring brake control valves.
Procedure and Standards
Certain air valves are subject to a slight amount of leakage and this is not a deficiency.
Deficiency
Deficiency
Category
1
Control valve:
a.
on a motor vehicle unable to be operated from the driving
position.
Major
b.
insecure.
Major
c.
fractured, cracked, damaged or excessively corroded.
Major
d.
impeded in its travel.
Major
e.
leaking.
Major
f.
excessive wear in the gate or lever locating mechanism.
Major
g.
malfunctioning.
Major
| [] | [] | [] | [] | train |
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41 Condition of Chassis
Application
This inspection applies to all vehicles and trailers.
Procedure and Standards
For integral construction the term chassis should also be taken to apply to the underframe.
For vehicles without a chassis those parts of the body must be examined which take the place of
the chassis.
A missing chassis crossmember is not a deficiency but it is subject to notifiable alteration
procedure which may result in a vehicle being down plated (inform the presenter to submit a
VTG10 using form VTG57).
When assessing corrosion it must only be regarded as a deficiency if it is sufficiently
advanced to obviously impair the strength of a load bearing member.
Deficiency 2 also includes sliding bogies and their locking mechanisms. It also includes
the operating mechanism to move the bogie (these are normally air chambers) where detachment
is likely (2aii).
Seddon 6 x 2 has a ‘H’ section crossmember fitted forward of the drive axle, there are 2 holes
in the bottom flange on each side of the chassis frame and crossmember which were originally for
securing the steel spring suspension front spring bracket to the chassis frame. When air
suspension is fitted there is no requirement to fit bolts in these 2 holes.
| [] | [] | [] | [] | train |
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41 Condition of Chassis
Deficiency
Deficiency
Category
1
Any main or cross member or outrigger which has
a load restraining device attached:
a.
(i)
fractured, cracked, corroded, or deformed.
Major
(ii)
fractured, cracked, with excessive corrosion, or
deformed, so that the control of the vehicle is likely to
be affected or the load will become insecure.
Dangerous*
2
Frame and/or cross member fastenings:
a.
(i)
insecure flitch plates and/or fastenings or welds
breaking away.
Major
(ii)
insecure flitch plates and/or fastenings or welds
breaking away so that the control of the vehicle is likely
to be affected or the load will become insecure.
Dangerous*
3
Integral body replacement panels:
a.
(i)
of an obviously unsuitable material.
Major
(ii) of an obviously unsuitable material and stability
impaired.
Dangerous*
b.
(i)
not adequately secured by an appropriate method.
Major
(ii) not adequately secured by an appropriate method and
stability impaired.
Dangerous*
| [] | [] | [] | [] | train |
hgv_manual | 121 | 122 | 941 | 154 | 01/06/2024
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42 Electrical Wiring and Equipment
Application
This inspection applies to all vehicles and trailers.
Procedure and Standards
If the battery is only held in place by the cables and by a lip on the carrier this cannot be
considered to be secure.
Where it is not possible to inspect batteries for condition and leaks every effort should be made to
inspect the area where the batteries are installed to confirm there are no signs of leakage.
When checking the condition and security of the wiring, care needs to be taken when inspecting
the high voltage systems of Hybrid Electric Vehicles and Electric Vehicles. These high voltage
wires are colour coded orange.
A trailer electrical socket with a defective or missing cover flap that incorporates a lug and
spring to hold the plug in place is not considered to be a defect.
| [] | [] | [] | [] | train |
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42 Electrical Wiring and Equipment
Deficiency
Deficiency
Category
1
Wiring:
a.
(i)
chafing, damaged or deteriorated insulation.
Minor
(ii)
chafed, damaged or deteriorated insulation, which is likely to
cause a short circuit fault.
Major
(iii)
chafed, damaged or deteriorated insulation, with obvious risk of
fire.
Dangerous
b.
(i)
not adequately secured.
Minor
(ii)
not adequately secured with fixings touching sharp edges and or
connectors likely to be disconnected.
Major
(iii)
not adequately secured and wiring likely to touch hot or rotating
parts or the ground.
Dangerous*
2
Battery:
a.
(i)
and/or carrier insecure.
Minor
(ii) and/or carrier insecure and likely to become displaced or cause
a short circuit.
Major
b.
case leaking.
Major
c.
switch or fuse defective.
Major
3
A trailer electrical socket:
a.
(i)
insecure.
Minor
(ii) insecure and likely to become detached.
Major
b.
(i)
damaged or deteriorated.
Minor
(ii) damaged or deteriorated to the extent that the connecting lead
cannot be securely connected.
Major
4
A Power train:
a.
insecure.
Major
b.
presents a risk of fire or injury.
Dangerous
| [] | [] | [] | [] | train |
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43 Engine and Transmission Mountings
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Application
This inspection applies to all vehicles, including Hybrid Electric Vehicles and Electric Vehicles.
Where there is separate power train equipment this should be treated as an engine/transmission.
Procedure and Standards
Serious fractures in clutch or bell housings which affect the security of the engine or gearbox
are to be considered a deficiency.
Deficiency
Deficiency
Category
1
Any mounting or subframe:
a.
(i)
securing nuts/bolts loose or missing.
Major
(ii)
securing nut/bolts loose or missing to such an extent
Dangerous*
that road safety is endangered.
b.
(i)
cracked or fractured.
Major
(ii)
cracked or fractured to such an extent that road safety
Dangerous*
is endangered.
c.
(i)
badly deteriorated.
Major
(ii)
badly deteriorated to such an extent that road safety is
Dangerous*
endangered.
| [] | [] | [] | [] | train |
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44 Oil Leaks
Application
This inspection applies to all vehicles and trailers.
Procedure and Standards
Check for oil leaks without operating any equipment other than the engine which may be run at
tick-over speed.
Very bad oil leaks are a reason for refusing to carry out the test. If the test is suspended for
this reason the presenter will be notified of this using form VTG12.
Temporary means of preventing leaked oil reaching the ground such as fabricated drip trays
consisting of sheet metal supported by wire strands are not acceptable. This does not apply to
permanent fittings such as drip trays for feed pipes on tankers.
Fabricated repairs to an oil pipe which effectively stop an oil leak are acceptable.
Deficiency
Deficiency
Category
1
(i)
Any oil leak which can deposit oil at a rate in excess of a 75mm Major
diameter pool in 5 minutes or a number of leaks which
collectively would deposit oil in excess of this.
(ii)
Any oil leak which can deposit oil in a continuous flow or
Dangerous
constitutes a serious risk of fire.
| [] | [] | [] | [] | train |
hgv_manual | 125 | 126 | 1,814 | 305 | 01/04/2025
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45 Fuel Tanks and System
Application
This inspection applies to all fuel tanks which are permanently attached to vehicles and to
trailers, including gas fuel tanks and cylinders, bottles and other types of fuel container.
For Hydrogen Fuel Cell vehicles, hydrogen tanks will be classed as fuel tanks.
Procedure and Standards
Seepage is not a deficiency.
Fabricated and "emergency" fuel caps are acceptable provided that they function correctly.
Where possible the tank cap should be opened to check the sealing arrangements.
Very bad fuel leaks are a reason for refusing to carry out the test. If the test is suspended for
this reason the presenter will be notified of this using form VTG12.
A fuel leak caused by a defect contaminating the road surface will be considered a hazard to
other road users.
If the vehicle is powered by gas and suffers a leak this should be treated in the same manner
as a normal fuel leak and VTG12 action taken. The vehicle should be moved to a well ventilated
area away from people and buildings. If the leak is of a serious nature evacuate the building.
It is not necessary to run the engine but if a leak is present when the engine is running this is
considered a deficiency under 2a.
It is not necessary to run combustion heaters as part of this inspection.
If a fuel tank assembly is seen to be holed, but the hole is above the fuel level, this is
considered a deficiency under 1d.
Where possible, LPG, CNG, LNG and Hydrogen tanks should be inspected for damage
(including dents) and corrosion. There will only be a deficiency where damage and/or corrosion is
considered excessive.
Note: corrosion will only normally apply to type 1 (steel tanks).
| [] | [] | [] | [] | train |
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45 Fuel Tanks and System
Deficiency
Deficiency
Category
1
Fuel tank:
a.
strap or support broken or missing.
Major
b.
so insecure on its mountings that it is likely to drop away partially
or completely when the vehicle is used.
Dangerous*
c.
heat shield missing, or defective to such an extent it constitutes
an obvious fire risk.
Dangerous
d.
defective such that leakage of fuel is possible.
Major
e.
LPG/CNG/LNG/Hydrogen tank excessively damaged and/or
corroded
Major
2.
Fuel System:
a. (i) leaking and does not represent an obvious hazard to other road
users.
Major
(ii) leaking and represents an obvious hazard to other road users.
Dangerous
b. (i) pipes damaged (restricted/chafed) or so positioned that they are
fouled by moving parts of the vehicle.
Minor
(ii) pipes so damaged (restricted/chafed), insecure or with an
inadequate repair, such that they are likely to fail and leak which
would cause danger to people on the vehicle or to other road
users.
Major
3.
Filler Cap:
a.
missing.
Dangerous
b.
does not fasten securely:
• by a positive means, or
• such that pressure is not maintained on the sealing
arrangement.
Major
c.
sealing washer torn, deteriorated or missing, or a
mounting flange/sealing method defective such that leakage of
fuel is possible.
Major
| [] | [] | [] | [] | train |
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