IICL Chassis Inspector Exam 2023 with verified question and answers

What is traction control? Helps the ABS improve vehicle traction by minimizing wheel slip on the drive axle during acceleration. What is ABS? Antilock braking systems are electronic systems that monitor and control wheel slip during vehicle braking. What are the components of ABS? electronic control unit (ECU), wheel speed sensors, modulator valves, exciter rings In ABS, what is the function of the electronic control unit (ECU)? Processes all ABS info and signal functions. Receives and interprets voltage pulses generated by the sensor pickup as the exciter teeth pass by, and uses this info to determine: (a) impending wheel lock, and (b) when/how to activate the ABS modulator valves. In ABS, what is the function of the modulator valves? Regulate air pressure to the brakes during ABS action. ECU commands mod valve to either change the air pressure to the brake chamber, or hold the existing pressure. In ABS, what are the 2 main components of the wheel speed sensors? (1) exciter, and (2) pickup In ABS, what is an exciter? A ring with notched teeth, also known as sensor ring, tooth wheel, tone ring, and exciter. In ABS, what is an pickup? Commonly called "the sensor" which contains a wire coil/magnet assembly, which generates pulses of electricity as teeth of the exciter pass in front of it. Which pin/wire is the power supply for ground on a 7-way plug? Pin 1 - white Which pin/wire is the power supply for stop and antilock on a 7-way plug? Pin 2 - red Which pin/wire is the power supply for power for electronic control unit (ECU) on a 7-way plug? Pin 3 - blue Which pin/wire is the power supply for identification, front and intermediate markers, front clearance, rear markers, license, tail and rear clearance on a 7-way plug? Pin 4 - brown Which pin/wire is the power supply for right directional on a 7-way plug? Pin 5 - green Which pin/wire is the power supply for left directional on a 7-way plug? Pin 6 - yellow Which pin/wire is the power supply for ABS warning light on a 7-way plug? Pin 7 - green/white What is the transition area? Location where the gooseneck meets the main rails What is a "horn" on a chassis? Large gathering structure extending above the top flange of the front of the chassis. It is a gathering device used to guide containers lifted on/off chassis, and to restrict forward movement. What is a kingpin? Critical structural member and connecting link between the chassis and the tractor fifth wheel. What is the inspection criteria for kingpin? Excessive wear beyond acceptable limits; chipped, broken, or cracked collar; looseness in upper coupler construction What is the required diameter of a kingpin? Upper section: between 2-11/16" & 2-7/8" Lower section: between 1-7/8" & 2" What is the inspection criteria for the upper coupler plate? Examine for gouges from fifth wheel, lubricated with grease, excessive/uneven wear, dishing, bulging, or distortion upwards. Check for corrosion and/or blockage of drain holes. What is the inspection criteria for the main rails? Sight along main rails to notice deformation (twist, bow, dent, or bend) in framework; examine frame welds for cracks What is the deciding factor in repairing main rails? Rails must be repaired when deformation influences the ability of a container to be seated properly and secured to the chassis, or its ability to track properly. What is the inspection criteria for the landing legs? Inspect support mounting brackets for bending and tight bolts; bolt holes on brackets and legs are same size; missing/damaged bolts replaced; uneven height; out of alignment (out of plumb condition in all directions) What are the components of the landing gear? Landing leg brace (diagonal or cross brace), landing legs, gear box, cross shaft, crank handle, crank handle retainer, sand shoes (or wheels), sand shoe axle What is the inspection criteria for ICC bumpers? Must not lie more than 22" from road surface What is another name for ICC bumper? Under ride protection What is the maximum height of an ICC bumper from the road surface? 22" Under USDOT rules, what are the requirements of ICC bumper measurements? a) Must extend to within 4" of max width of chassis, but not extend beyond side extremity b) Must be within 12" of the rear extremity When must a damaged ICC bumper be repaired? Bending of hangars or struts to where protection zone has been displaced 2" or more from original position; damage causes safety hazard What is the inspection criteria for mud flaps? a) Cover full tread of tire b) Tear more than 2" in length c) Approximately 6" above road What is the inspection criteria for mud flap brackets? Check for deformity which causes mud flap or brackets to touch tires, ground/road or under ride protection. What are examples of securing devices? Twistlocks, locking pins, index pins What are the restraining regulations for securing devices? Must restrain a container from moving more than 1/2" in any horizontal direction or 1" vertically while chassis is in motion What is the inspection criteria for securing devices? Determine if operate properly; look for missing components, bent shanks, bent levers, bent latches; check for missing springs, retainers, or handles; ensure there are no thrust collar weld separations. What are the 2 types of slider assemblies? Sliding bogie and sliding frame (extendable) What is a sliding bogie? Structure that moves running gear forward and aft to change the chassis wheelbase and by modifying weight distribution to allow carriage of different loads. Also know as a sliding tandem. What is a sliding frame? Structure on an extendable chassis that adjusts (telescopes) the frame length to accommodate containers of various lengths What is the method of locking sliders to prevent movement? Align holes between chassis mainframe and the running gear. When holes are properly aligned, locking pin or pins penetrate the holes on both sides of the slider frame and locks the slider assembly into desired position. What is the inspection criteria for slider locking pins? Check to see if bent or skewed; verify pins extend approx. equally through their mating holes in the slider frame and the body rails; How far should locking pins protrude past the face of the rails? Minimum of 1/4", exclusive of the chamfered edges of pins What is the inspection criteria for slider hold down clips? Check the retainer bolts for proper tightness; evidence of rust build up between the plates and chassis frame What bolt size and torque is required for slider hold down clips? 5/8" hex head, grade 5 bolt with 90-120 lb-ft torque What is the inspection criteria for slider stop plates? Positioned approx. 1/2" past forward and rear slider positions; look for fractured welds or material deformation caused by sever impact of running gear frame during sliding procedure What is the inspection criteria for slider indexing holes? Holes cannot be worn or elongated in the longitudinal direction more than 1/8"; vertical elongation is ok What is the maximum allowed slider frame clearance between main rail? Variations over 1/8" signify the need for a more thorough inspection to determine cause What components are inspected during check of braking system? Glad hands for broken parts, damaged seals, worn grommets or loose fittings; condition of brake hoses for chafing, kinking, or other damage; air leaks with tank filled; cracked or broken drums or severe heat checks; blown diaphragms; chamber leaks; bent push rods; missing broken or disconnected parts What is the maximum acceptable leak rate of the charged air system (brakes)? Not to exceed 3 psi per minute (as measured with pressure gauge) What is involved in checking brake adjustment? Observe camshaft rotation; condition of bushings; push rod travel; inspect relay valves for housing cracks and leakage at hose connections What is the inspection criteria for brake chambers? Check for proper alignment with slack adjustor; pushrod should be in line with longitudinal centerline or brake chamber. If pushrod is at an angle, there is a misalignment; corrosion and operation; check yoke and clevis assembly for jam nut securement, clevis pin, and cotter pin; check service and emergency input ports on chamber; check air hose connection and fittings What is the inspection criteria for air hoses? Condition of the rubber air hose extensions; synflex air lines and tension springs; kinking of hoses; unusual abrasion; excessive wear or cutting of hose; excessive droop; inadequate length What is the maximum allowable separation between brake lining and shoe? 1/16" (provided that lining is firmly attached to shoe) What is the inspection criteria for brake linings? Visually check for thickness; oil/grease saturation; separation from shoes; cracking; chipping. What is the minimum acceptable brake lining thickness? No less than 1/4" at the shoe center What is heat checking on a brake drum? Normal condition where the appearance of numerous short, fine hairline cracking on the braking surface of drum appear. What is the maximum diameter of braking surface of a drum? 0.120" over nominal new diameter unless stated otherwise on casting What is the maximum allowance of braking surface of a drum when resurfacing? .040" under max diameter needed for additional wear OR total of 0.080" beyond original diameter What is the acceptable wheel adjustment endplay when checking or reinstalling bearings? Allowable endplay is between 0.001" to 0.005" (with dial indicator) What is excessive wheel play in bearings a sign of? Improper wheel torque and/or possible bearing/cone damage What is the minimum acceptable tire tread groove pattern depth? 2/32" (when measure in major tread groove) What is the inspection criteria for tires? Examine for adequate tread, cuts, gouges (where fabric is evident by probing), excessive abrasions, flat spts, weather checking, regrooving damage, and other signs of tire wire, damage, or abuse. What is the maximum acceptable difference in flat spot tread depth? Flat spots with greater than 3/32" depth compared to remaining tread What percentage of conspicuity coverage is required for overall length of vehicle? At least 50% What percentage of conspicuity coverage is required for rear bolster and under ride protection? Full width of rear bolster and under ride protection What are FMCSA inspection requirements? Each chassis must be inspected at least 1 per year What does FMCSA stand for? Federal Motor Carrier Safety Administration, which operates under U.S. Dept of Transportation (USDOT) FMSCA assumed regulatory authority over chassis operations from what previous administration? Federal Highway Administration (FHWA) in 1/1/2000 What does NHTSA stand for? National Highway Traffic Safety Administration What does NHTSA regulate? What components a chassis must have and how they must perform as of the date of their manufacture What does FMCSA regulate? Conditions the chassis must meet when on the road, regardless of when built. What does FMVSS stand for? Federal Motor Vehicle Safety Standards What does BIT stand for? Biennial Inspection of Terminals What does CVSA stand for? Commercial Vehicle Safety Alliance When is a BIT required? Vehicles must be periodically inspected with 90-day intervals or sooner, if necessary, to ensure safe operation. What are the minimum inspection requirements for a BIT? a) brake adjustment b) brake system components and leaks c) steering and suspension systems d) tires and wheels e) vehicle connecting devices (fifth wheels, kingpins, pintle hooks, etc.) What must a BIT report include? a) identification of vehicle b) date and nature of each inspection and repair performed c) signature of authorized rep How long must BIT reports be retained? At least 2 years What are the FMCSA record keeping requirements? Motor carrier must retain the original copy of report for 14 months following date of inspection. Drivers who receive docs must sign and the motor carrier must maintain that receipt for 12 mos. from date of receipt. What is the controlling document for chassis inspections? 49 CFR 396.17 (FMCSA periodic inspection requirements)