hgv-inspection-manual
The latest UK HGV MOT inspection manual.
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HeavyGoods Vehicle (HGV) InspectionManual IssueDateFebruary2017 SectionBPage i
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Heavy Goods Vehicle Inspection Manual About this Manual 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. 01/02/2021 1of 4Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual About this Manual 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. 01/06/2024 2of 4Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual About this Manual 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. 01/06/2024 3of 4Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual About this Manual 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 byDriverandVehicleStandardsAgencystaff.Radiosand telephones must not be used whilst vehicles are undergoing test. 01/04/2025 4of 4 Document Uncontrolled when printed
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Heavy Goods Vehicle Inspection Manual Revision Record Section Revision Section Title Description of Change Number Date About this ManualPage 2 - Deficiency Categorisation – last sentence from minor01/06/2024 deficiencies amended to cater for electronic test certification. Seat Belts &Page 2, note in procedure and standards for cuts and 01/06/2024 Supplementarydamage assessment is updated to clarify the importance Restraint Systemsof tensile strength. Page 2, note added to procedure and Standards “Air bags 03 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. Size and Type ofPage 1, note added to use markings encountered “some 01/06/2024 07 Tyrestyres may be branded for a tyre recommended use while still suitable for other applications”. Glass and View ofPage 2, note added to clarify the standard to apply for view to01/06/2024 23 the Roadfront on dash mounted monitors will dependant on the function that the system provides. Speedometer/Page 1 and 2, information layout reformatted with reference01/06/2024 26 Tachographto analogue and digital tachographs removed. Removed duplicated note for the checks on DIL switch covers. Electrical WiringPage 1, note added to procedure and standard “A trailer 01/06/2024 and Equipmentelectrical socket with a defective or missing cover flap that 42incorporates a lug and spring to hold the plug in place is not considered to be a defect.” LampsPage 2, note added in respect of inoperative non obligatory01/06/2024 lamps. 63 Page 2 reversing lamps fitment note “ but all must work” removed. 66Direction IndicatorsPage 2, note added in respect of inoperative non obligatory 01/06/2024 and Hazard lamps. Warning Lamps SectionSection Title Description of Change Revision Number Date About this ManualPage 4 of 4 – Scope of Inspections – Added to paragraph in01/04/2025 respect of regulatory requirements which update this manual compared with type-approval. Interpretation ofPage 2 added Note: Fuel tanks and gas cylinders will only be01/04/2025 Termssubject to visual inspection for corrosion. Size and Type ofPage 10 of 10 – Deficiency 1a (ii) After the words ‘axle 01/04/2025 7 Tyresweight and is loaded’ new wording is added which states ‘at least 10%’. Sideguards, rearComplete re-write of the section, improving flow. 01/04/2025 under-run devicesIncorporated new list of exempted vehicles for sideguards & bumper bars from 01/04/25. 09 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. 01/07/2025 1 of 2Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual Revision Record Glass and View toPage 3, added Monitors for indirect vision devices 01/04/2025 23 the Road Pressure/VacuumPage 1, added “whether one is attached or not” to clarify the01/04/2025 34Warning and Buildpressure build up time for towing vehicles. Up Fuel Tanks andPage 1 – Application, Hydrogen fuel cell tanks to be 01/04/2025 Systems considered fuel tanks. Page 1 – Procedure and Standards, paragraph added for 45 LPG, CNG, LNG and Hydrogen tanks now testable. Page 2 – RFR added for these tanks being excessively corroded and/or damaged. Brake Systems andPage 1 added words in bold. A pipe with its wall thickness 01/04/2025 Componentsreduced by more than one third of its original thickness is 59 considereda majoror dangerousdeficiencydepending upon severity. Service BrakePage 2 Load simulation – added line to state that the vehicle01/04/2025 Performanceshould be loaded. Added “drive” to axle requiring more than 65% of design axle weight. 71Page 2 Load sense valves – added line to state that vehicle should be loaded and removed “immediately” before brake test. SectionSection TitleDescription of Change Revision Number Date All sectionsRe-formatted some of sections due to showing incorrectly in01/07/2025 PDF conversion Interpretation ofAdded air tanks to the page 1 for corrosion assessment 01/07/2025 terms Size and Type ofPage 1. Note added to clarify load index applies to GB plated01/07/2025 Tyres weights 07 Sideguards, rearParagraph on page 2 outlining that vehicles/trailers type 01/07/2025 under-run devicesapproved with sideguards must remain fitted for annual test & bumper bars from 1stApril 2025. 09 01/07/2025 2 of 2Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual 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. 01/07/2025 1of 5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual 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. 01/02/2021 2of 5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual 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. 01/04/2023 3of 5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual 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 theapplicationsection of this manual it refers to all types ofmotor vehicle. 01/05/2022 4of 5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual 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. 01/05/2022 5of 5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual List of Inspections 1 *Registration Plate 39Hand Operated Brake Control Valves 2Not allocated 40Not allocated 3 *Seat Belts and Supplementary Restraint 41Condition of Chassis Systems 42Electrical Wiring and Equipment 4Not allocated 43*Engine and Transmission Mountings 5 *Exhaust Emissions 44Oil Leaks 6Road Wheels and Hubs 45Fuel Tanks and Systems 7Size and Type of Tyres 46*Exhaust Systems and Nuisance 8Condition of Tyres 47Not allocated 9Sideguards, Rear Under RunDevices 48Suspension and Bumper Bars 49Not allocated 10Spare Wheel and Carrier 50Not allocated 11Vehicle to Trailer Coupling 51Not allocated 12Trailer parking, Emergency Brake and Air 52Not allocated Line 53Axles, Stub Axles and Wheel Bearings Connections 54Steering 13Trailer Landing Legs 55Not allocated 14Spray Suppression, Wings and Wheel 56Not allocated Arches 57Transmission 15*Cab Security 58Additional Braking Devices 16*Cab Doors 59Brake Systems and Components 17*Cab Floor and Steps 60Not allocated 18*Seats 61Not allocated 19Security of Body, Containers and Crane 62Markers and Reflectors Support 63Lamps Legs 64Not allocated 20Condition of Body 65Not allocated 21Not Allocated 66Direction Indicators and Hazard Warning 22*Mirrors and Indirect Vision Devices Lamps 23*Glass and View of the Road 67*Aim of Headlamps 24Not allocated 68Not allocated 25*Windscreen Washers and Wipers 69Not allocated 26*Speedometer/Tachographs 70Not allocated 27*Horn 71Service Brake Performance 28*Driving Controls 72*Secondary Brake Performance 29Not allocated 73Parking Brake Performance 30*Steering Control 74Other Dangerous Defects 31Not allocated 32Not allocated 33*Speed Limiter 34*Pressure/Vacuum Warning and Build Up 35Not allocated 36*Hand Lever Operating Mechanical Brakes and Electronic Park Brake Controls 37*Service Brake Pedal 38Service Brake Operation *Inspection does not apply to trailers 01/02/2021 1 of 1Document Uncontrolled When Printed
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Heavy Goods Vehicle Inspection Manual 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 isNOTmarked 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. 01/02/2021 1of5 DocumentUncontrolledWhenPrinted
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Heavy Goods Vehicle Inspection Manual Standards for Prohibition Issue at Statutory Test ManualReference DeficiencyCriteria Deficiency Detachment imminent where the applicable drivers IM 3 2a (ii)* and/or passengers seat will be occupied during the Seat Belts 6a* journey following test. Retaining ring is excessively displaced from its 1a* IM 6 seating and total displacement is imminent. Road Wheels and Hubs Failure or detachment imminent. 2d* 1d* IM 7 Directional stability is obviously, significantly 1e* Size and Type of affected. 1f* Tyres 2* A tyre so severely damaged that failure of the tyre 1c* is likely. IM 8 Condition of TyresTyre tread worn below the legal minimum on any tyre fitted to a steered axle and/or 50% or more of 1h* the total number of tyres fitted to non-steered axles. IM 9 Sideguards, Rear Use of the vehicle or trailer poses an imminent 3b* Under-Run Devices danger of injury to any person. 5b* & Bumper Bars IM 10 1(iii)* Spare Wheel &Detachment imminent. 2(ii)* Carrier 1a (ii)*,1b (ii)* 1c (ii)*,1d (ii)* 1e* IM11 Detachment imminent. Vehicle to Trailer 2a (ii)*, 2b (ii)* Coupling 2e (ii)* 2g* 01/02/2021 2of5 DocumentUncontrolledWhenPrinted