Heavy Vehicle DOT Pre‑Trip PDF

Complete DOT-compliant pre-trip inspection procedures for heavy commercial vehicles

DOT Requirements

This inspection must be completed before each trip per 49 CFR 396.13. Heavy vehicles including tractors, straight trucks, dump trucks, and tankers require special attention to air brake systems, coupling devices, and load securement.

Document Verification

  • Verify CDL license is current with proper endorsements for vehicle type.
  • Check medical examiner's certificate expiration date.
  • Confirm vehicle registration and insurance documents are present.
  • Review previous Driver Vehicle Inspection Report (DVIR).
  • Verify all previous defects have been corrected and signed off.
  • Check for any special permits (oversize, overweight, HazMat).
  • Ensure Electronic Logging Device (ELD) is operational.

Engine Compartment (Hood Open)

  • Check engine oil level - should be between MIN and MAX marks.
  • Inspect coolant level in surge tank (never remove radiator cap on hot engine).
  • Verify power steering fluid reservoir level.
  • Check windshield washer fluid and top off if needed.
  • Inspect all belts for proper tension and signs of wear or fraying.
  • Check all hoses for cracks, leaks, or loose clamps.
  • Verify air compressor is securely mounted and belt driven properly.
  • Look for any oil, coolant, or fuel leaks.
  • Check battery terminals for corrosion and secure connections.

In-Cab Inspection & Controls

  • Adjust seat for proper reach to all controls.
  • Test seat belt for proper operation and secure latching.
  • Adjust all mirrors for maximum visibility.
  • Verify fire extinguisher is charged, accessible, and properly rated.
  • Check for three reflective triangles in proper case.
  • Ensure spare electrical fuses are available (if applicable).
  • Start engine and check all gauges come to normal range.
  • Test horn for proper operation.
  • Check windshield wipers and washer operation.
  • Test all interior lights and controls.

Air Brake System Tests (Engine Running)

  • Build air pressure to governor cutoff (typically 120-140 psi).
  • With engine at operating RPM, air pressure should build from 50-90 psi within 3 minutes.
  • Test air leakage rate - with brakes released, loss should not exceed 3 psi/minute.
  • Apply service brake - air loss should not exceed 4 psi/minute.
  • Test low air warning device - should activate between 55-75 psi.
  • Check spring brake activation - should apply between 20-45 psi.
  • Listen for air leaks around brake chambers and air lines.
  • Check slack adjusters for proper adjustment (manual and automatic).
  • Verify brake push rod travel is within specifications.

External Walk-Around - Front of Vehicle

  • Check steering box for leaks and secure mounting.
  • Inspect steering linkage for wear, damage, or loose components.
  • Verify front axle springs, spring hangers, and U-bolts are secure.
  • Check shock absorbers for leaks and secure mounting.
  • Inspect front tires for proper inflation (use gauge, not thumper).
  • Check tread depth - minimum 4/32" on steer axle.
  • Verify no recaps or regrooved tires on steer axle.
  • Inspect for cuts, bulges, or irregular wear patterns.
  • Check all lug nuts are present and show no signs of looseness.
  • Verify hub oil seals are not leaking.

Side of Vehicle Inspection

  • Check fuel tanks are secure with no leaks.
  • Verify fuel caps are on tight and seals properly.
  • Inspect drive shaft for damage or loose U-joints.
  • Check exhaust system is secure with no leaks.
  • Verify DEF tank level and cap secure (if equipped).
  • Inspect frame for cracks, damage, or illegal welds.
  • Check all lights and reflectors are clean and undamaged.
  • Verify mud flaps are present and not damaged.
  • Inspect cargo area for cleanliness and damage.
  • Check all cargo doors latch securely.

Coupling System (Tractor-Trailer)

  • Verify fifth wheel is properly greased.
  • Check fifth wheel mounting bolts are tight.
  • Ensure no damaged or missing parts on fifth wheel.
  • Verify locking jaws are around kingpin properly.
  • Check release handle is in locked position.
  • Ensure no gap between upper and lower fifth wheel plates.
  • Verify air lines are properly connected with no leaks.
  • Check electrical cord is plugged in and secure.
  • Test trailer air brakes and spring brakes.
  • Verify all trailer lights are functioning.

Rear of Vehicle & Final Checks

  • Check all rear lights are clean and functioning.
  • Test brake lights with helper or using reflection.
  • Verify turn signals work properly.
  • Check license plate is clean and visible.
  • Inspect rear tires for proper inflation and condition.
  • Verify tread depth minimum 2/32" on drive axles.
  • Check for proper dual spacing (no kissing).
  • Test service brakes at slow speed.
  • Verify parking brake holds vehicle.
  • Complete and sign Driver Vehicle Inspection Report.

Documentation & Reporting

  • Record all defects found during inspection.
  • Note corrective actions taken or needed.
  • Complete DVIR with vehicle identification and mileage.
  • Sign and date the inspection report.
  • Report any defects to maintenance immediately.
  • Do not operate if defects affect safety or could cause breakdown.
  • Keep copy of DVIR in vehicle for minimum 24 hours.
  • File original DVIR per company policy (minimum 90 days).
  • Generate PDF copy for electronic records if required.
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