HGV DEFECTS
Updated: 2 days ago
WHAT TO DO WHEN SOMETHING GOES WRONG.
TYRES, BREAKDOWNS & EMERGENCIES.
Something will eventually go wrong.
A warning light will appear.
You'll hear an air leak.
A tyre will look wrong.
A light will fail.
The vehicle will suddenly feel different.
You'll find a defect during your walkaround.
Or you'll be standing beside a broken-down lorry wondering what happens next.
You are not expected to be a mechanic.
You are expected to take vehicle safety seriously, identify problems that should reasonably be detected, report them correctly and make sensible decisions when something isn't right.
The most important rule is simple:
IF YOU ARE NOT SATISFIED THAT THE VEHICLE IS SAFE TO DRIVE, DO NOT JUST DRIVE IT AND HOPE FOR THE BEST.
DEFECTS CAN APPEAR AT ANY TIME
Your daily walkaround check is essential, but roadworthiness doesn't end when the walkaround is finished.
A vehicle can develop a defect:
leaving the yard;
during loading;
after unloading;
after hitting a pothole;
after striking debris;
during a long journey;
after parking;
after another driver has used it; or
at any other point during the working day.
Remain alert to changes in the vehicle throughout your shift.
WHAT IS A DEFECT?
A defect is a fault or condition affecting the vehicle, trailer or equipment.
It might involve:
tyres;
wheels;
brakes;
steering;
suspension;
lights;
reflectors;
mirrors;
windscreen;
wipers;
washers;
coupling equipment;
bodywork;
doors;
load-security equipment;
air systems;
electrical systems;
exhaust;
emissions systems;
number plates;
tachograph;
safety equipment; or
another component.
Some defects are relatively minor.
Some make the vehicle unsafe.
Some may not look dramatic but can become extremely serious very quickly.
“CAN I DRIVE IT?”
This is one of the most important questions you'll encounter.
Unfortunately, the answer isn't always something a driver should try to determine alone.
Consider:
What exactly is wrong?
Does it affect safe control of the vehicle?
Could it deteriorate?
Does it affect brakes, steering, tyres, wheels or coupling?
Is anything loose?
Is anything leaking?
Is a safety-critical warning active?
Is the vehicle legally roadworthy?
What does the manufacturer say?
What does your company's defect procedure say?
Has a competent person assessed it?
There is an important difference between:
“The vehicle can physically move.”
and:
“The vehicle is safe and legal to drive.”
They are not the same thing.
IF IN DOUBT — REPORT IT
Drivers sometimes worry about reporting something that turns out to be harmless.
Don't.
It is better to report a concern and discover that it is acceptable than to ignore something safety-critical.
Report defects through your company's established system.
Depending on the business, this may involve:
defect sheet;
app;
electronic vehicle-check system;
transport manager;
workshop;
fleet manager; or
another nominated person.
Give useful information.
Instead of:
“Truck's making a noise.”
try:
“Knocking noise from front left when steering at low speed. Started after leaving customer. No warning lights showing.”
Clear information helps the person assessing the problem.
RECORD IT
If you identify a defect, make sure it is properly recorded where required.
Record:
vehicle registration/fleet number;
trailer identification where relevant;
date and time;
defect;
when you noticed it;
any warning displayed;
action taken; and
who you reported it to.
Photographs can also be useful where appropriate.
A verbal:
“I told somebody about it.”
is not a particularly strong defect-management system.
DEFECTS FOUND BEFORE DEPARTURE
If you find a defect during your walkaround:
identify it;
record it;
report it;
have it assessed/repaired as necessary; and
do not take the vehicle onto the road if it is unsafe or unroadworthy.
Do not simply clear the defect from an app because somebody says:
“We know about that one.”
A known defect is still a defect.
Follow the proper process.
DEFECTS THAT DEVELOP DURING THE JOURNEY
If something changes while driving, ask yourself immediately:
CAN I CONTINUE TO A SAFE PLACE, OR DO I NEED TO STOP NOW?
A safety-critical problem may require you to stop as soon as it is safe to do so.
Other faults may allow controlled movement to a safer stopping location.
The correct response depends on the fault and circumstances.
If unsure:
reduce risk;
find a safe place;
stop;
contact your operator/workshop; and
obtain competent advice.
WARNING LIGHTS
Modern HGVs can display an enormous amount of information.
Do not ignore a warning simply because the vehicle appears to be driving normally.
Warnings may relate to:
engine;
coolant;
oil pressure;
brakes;
ABS;
EBS;
steering;
transmission;
air pressure;
suspension;
emissions;
AdBlue;
electrical systems;
tyre pressure;
coupling; or
driver-assistance systems.
Different manufacturers use different displays and messages.
DON'T GUESS
If you don't recognise a warning:
find somewhere safe;
read the actual message;
consult the vehicle handbook/driver information;
contact the workshop/operator; and
follow competent advice.
Do not repeatedly dismiss a warning because pressing “OK” makes it disappear from the screen.
You have acknowledged the message.
You haven't repaired the fault.
RED WARNINGS
A red warning generally indicates a serious condition requiring immediate attention.
However, do not rely solely on colour.
Understand what the actual warning means for that vehicle.
If a warning instructs you to stop:
STOP AS SOON AS IT IS SAFE TO DO SO.
AIR PRESSURE
Compressed air is fundamental to HGV braking systems.
Be familiar with the vehicle's normal pressure range and warning systems.
Warning signs of an air-system problem may include:
low-pressure warning;
audible alarm;
pressure failing to build;
pressure dropping unusually quickly;
repeated compressor cycling;
obvious hissing;
brake problems; or
suspension problems.
IF AIR PRESSURE IS LOW
Do not simply drive away hoping it will build while you're moving.
Allow the system to build correctly and establish why pressure is low.
If pressure will not build normally, or drops abnormally:
report it and have the system assessed.
AIR LEAKS
HGV air systems make noises during normal operation.
Not every hiss means catastrophe.
But a persistent or excessive leak requires attention.
If you hear something unusual:
locate it only if safe to do so;
monitor the air-pressure gauges;
report the concern; and
obtain competent assessment.
Never put yourself underneath or between parts of a vehicle simply to investigate a noise unless the vehicle is properly secured and you are trained and authorised to be there.
BRAKE FAULTS
Brake defects are safety-critical.
Possible warning signs include:
brake warning lights;
ABS/EBS warnings;
unusual pedal behaviour;
vehicle pulling under braking;
poor braking performance;
excessive stopping distance;
burning smell;
smoke;
excessive heat;
unusual noises; or
abnormal air-pressure behaviour.
Do not “see how it goes” with a suspected serious brake problem.
Stop safely and report it.
ABS & EBS WARNINGS
ABS and EBS systems are important components of modern HGV braking and stability systems.
A warning may indicate that part of the system is unavailable or faulty.
The exact meaning and permissible action depend on:
the warning;
tractor;
trailer;
system fitted;
manufacturer; and
fault.
Do not make up your own rule such as:
“It's only an ABS light, so it's grand.”
Identify the warning and have the fault properly assessed.
BRAKE OVERHEATING
Brakes can generate enormous heat.
Warning signs may include:
strong burning smell;
smoke;
unusually hot wheel area;
reduced braking performance; or
heat noticeably affecting one wheel more than others.
Do not touch a brake, wheel or hub to see whether it is hot.
It may be extremely hot.
Stop safely, keep people away and obtain assistance.
If there is smoke or fire, treat the situation as an emergency.
STEERING FAULTS
Any significant change in steering deserves immediate attention.
Warning signs may include:
excessive free play;
unusual heaviness;
pulling;
vibration;
knocking;
steering warning lights;
difficulty maintaining direction; or
sudden change in steering behaviour.
Steering is safety-critical.
If you suspect a significant steering defect:
stop safely and report it.
SUSPENSION DEFECTS
Look and listen for:
vehicle leaning;
damaged springs;
displaced components;
air leaks;
suspension warning messages;
abnormal ride height;
damaged airbags;
unusual noises; or
tyres/bodywork making contact.
Suspension defects can affect:
stability;
steering;
braking;
tyre clearance;
axle loading; and
overall vehicle safety.
LIGHTING FAULTS
Check lights during your walkaround and remain alert to dashboard bulb-failure warnings.
Relevant lighting includes:
headlights;
sidelights;
tail lights;
brake lights;
indicators;
hazard lights;
marker lights;
fog lights;
number-plate lights; and
trailer lighting.
A failed lamp may appear minor compared with a brake defect, but vehicle visibility and signalling are safety issues.
Report and rectify faults appropriately.
TYRES — YOUR CONTACT WITH THE ROAD
Every tonne of vehicle, trailer and load ultimately meets the road through relatively small tyre contact areas.
Tyres deserve serious attention.
During checks, look at:
tread;
inflation;
sidewalls;
cuts;
bulges;
exposed cords;
embedded objects;
uneven wear;
valve condition;
twin tyres;
objects between twins; and
signs of overheating or damage.
HGV TYRE TREAD DEPTH
For heavy commercial vehicles in Ireland, tyres must meet the applicable legal tread requirements which is 1.6mm under Irish legislation.
Do not rely on memory or somebody else's opinion if a tyre is borderline.
Use an appropriate tread-depth gauge and check the relevant current legal requirement.
Remember that legal minimum does not necessarily mean desirable condition.
Company tyre-replacement policies may require action before the legal minimum is reached.
TYRE PRESSURE
Incorrect tyre pressure can affect:
handling;
braking;
tyre temperature;
fuel consumption;
wear;
tyre life; and
risk of failure.
Visual inspection alone cannot reliably establish exact pressure.
Use the correct pressure for:
vehicle;
axle;
tyre;
load; and
manufacturer's/operator's specification.
A tyre that “looks alright” may still be significantly underinflated.
CUTS, BULGES & SIDEWALL DAMAGE
Take sidewall damage seriously.
Look for:
cuts;
splits;
cracking;
bulges;
exposed cords;
impact damage; and
deformation.
A bulge can indicate structural damage inside the tyre.
Do not poke it, kick it and declare:
“That'll probably make it home.”
Have questionable tyre damage assessed by a competent person.
OBJECTS IN TYRES
If you find a nail, screw or other object embedded in a tyre:
don't automatically pull it out.
Removing it may cause rapid pressure loss.
Report it and obtain appropriate tyre assistance/assessment.
TWIN TYRES
Twin-wheel arrangements need particular attention.
Check:
both tyres;
pressure/condition;
adequate separation;
damage;
uneven wear; and
anything trapped between them.
OBJECTS BETWEEN TWINS
Stones and debris can become trapped between twin tyres.
This can damage the tyres and may eventually be thrown out with considerable force.
Do not put your hands between twin tyres or attempt unsafe roadside removal.
Report it and use a safe method/competent assistance.
WHEEL NUTS
Check for signs of wheel-nut movement or looseness.
Look for:
missing nuts;
loose nuts;
damaged studs;
rust trails;
shiny movement marks;
damaged wheel-nut indicators; and
indicators that no longer align as expected.
Wheel-nut indicators are useful aids.
They do not replace proper inspection.
A suspected loose wheel requires immediate attention.
WHEEL DAMAGE
Look for:
cracks;
distortion;
impact damage;
missing components;
unusual movement;
damage around stud holes; and
anything suggesting the wheel is not secure.
A wheel-related defect can become catastrophic.
Do not continue with a suspected serious wheel defect.
HOT TYRES, WHEELS & HUBS
Unusual heat can indicate problems including:
underinflation;
tyre damage;
brake binding;
bearing problems; or
other mechanical faults.
If one wheel position is behaving very differently from the others, investigate through the proper channels.
Do not touch potentially overheated components with your bare hand.
TYRE BLOWOUTS
A tyre failure at speed can be frightening.
Your priority is maintaining control.
If a tyre fails while driving:
keep control of the steering;
avoid panic;
avoid unnecessary sudden steering;
avoid inappropriate harsh braking;
reduce speed in a controlled manner;
use hazard lights as appropriate;
find the safest available stopping location; and
stop and assess the situation from a safe position.
The vehicle's reaction will depend on which tyre has failed, vehicle configuration, speed, load and road conditions.
Once stopped, do not place yourself in danger trying to inspect it.
NEVER CHANGE AN HGV TYRE UNLESS YOU ARE TRAINED, EQUIPPED AND AUTHORISED
HGV wheels and tyres are extremely heavy and can involve significant hazards.
Tyre inflation systems can contain enormous stored energy.
This is not the place for improvisation.
Use appropriate professional tyre assistance.
FLUID LEAKS
Take unexplained leaks seriously.
Possible fluids include:
diesel;
engine oil;
coolant;
hydraulic fluid;
AdBlue;
screenwash; and
other vehicle/body-system fluids.
Consider:
what is leaking;
quantity;
rate;
where it is coming from;
whether it presents a fire risk;
whether it creates a slippery road surface;
environmental risk; and
whether continued operation could damage the vehicle.
If you cannot identify it safely, don't guess.
OVERHEATING
If the engine temperature becomes abnormal or an overheating warning appears:
take the warning seriously;
stop safely as required;
follow manufacturer guidance;
contact the operator/workshop; and
allow competent assessment.
Never remove a pressurised cooling-system cap from a hot engine.
Hot coolant can cause severe burns.
BREAKDOWN — FIRST PRIORITY: YOU
A breakdown can happen anywhere.
Your first concern is not:
“How quickly can I get this delivery moving again?”
It is:
“How do I keep myself and everybody else safe?”
IF THE VEHICLE BEGINS TO FAIL WHILE MOVING
If possible:
remain calm;
maintain control;
signal appropriately;
avoid sudden manoeuvres;
move towards a safe stopping location;
use hazard lights where appropriate; and
consider the traffic around you.
If the vehicle cannot be moved safely, stop where necessary and immediately consider the danger created by its position.
ONCE STOPPED
Depending on circumstances:
secure the vehicle;
apply the parking brake;
switch off/isolate as appropriate;
use hazard lights;
wear hi-vis before entering a live traffic environment;
assess your location;
keep yourself away from moving traffic;
contact the operator/recovery provider;
contact emergency services where required; and
follow road/operator procedures.
MOTORWAY BREAKDOWNS
Motorways are particularly dangerous places to break down.
High traffic speeds mean the situation can become life-threatening very quickly.
If the vehicle is still controllable, aim to reach the safest available location rather than stopping in a live lane where this can safely be avoided.
Depending on the road, this may include:
service area;
exit;
hard shoulder where provided;
emergency area; or
another designated refuge.
Once stopped:
use hazard lights;
make the vehicle as visible as appropriate;
BUT! Never place a warning triangle on a motorway.
assess whether it is safer to remain in or leave the cab;
keep away from live traffic;
never stand between your vehicle and approaching traffic;
contact the relevant assistance; and
follow official motorway/emergency guidance.
DO NOT ASSUME THE HARD SHOULDER IS SAFE
Vehicles are struck on hard shoulders.
Treat it as a high-risk environment.
Do not wander around the vehicle unnecessarily.
IF YOU BREAK DOWN IN A LIVE LANE
If you are unable to reach a safer location and are stopped in a live traffic lane, treat the situation as an emergency.
Make yourself/vehicle visible as appropriate and contact emergency services/road authorities promptly.
Do not attempt repairs while exposed to moving traffic.
WARNING TRIANGLES
NEVER place a warning triangle on a motorway. Use your own judgement to place one on a B road. The recommended distance for placement is 50 metres.
However. The act of placing one can expose you to far greater danger than remaining in a protected location.
Follow the applicable official road-safety guidance for the road and situation.
Your safety comes first.
FIRE
If you see smoke or suspect fire:
stop as safely as possible;
switch off the vehicle if appropriate;
get yourself and others away;
call emergency services;
warn others where this can be done safely; and
do not put yourself at risk attempting to save the vehicle or load.
A fire extinguisher may be useful for a very small, manageable fire only if it is safe and you are competent to use it.
Do not allow a small extinguisher to convince you to remain beside a developing HGV fire.
Vehicles and loads can be replaced.
You cannot.
RECOVERY
When calling for recovery, be ready to provide useful information:
vehicle registration;
fleet number;
vehicle type;
trailer type;
loaded or empty;
approximate weight where relevant;
nature of fault;
exact location;
road number;
direction of travel;
nearest junction/landmark;
whether you're in a dangerous position;
whether traffic is obstructed;
whether tyres/wheels are damaged;
whether steering/brakes/air are affected; and
whether specialist recovery may be required.
If carrying livestock, dangerous goods, temperature-controlled goods or another sensitive load, tell the relevant people immediately.
The recovery requirement may be very different.
DON'T TRY TO BE A ROADSIDE MECHANIC
A driver may be able to deal with simple matters within their competence and company procedures.
But there are jobs you should not improvise.
Do not attempt work involving systems or equipment you are not trained, authorised and equipped to handle.
That can include:
brakes;
steering;
pressurised air systems;
heavy wheels/tyres;
suspension;
electrical/high-voltage systems;
fuel systems;
hydraulic systems;
coupling mechanisms;
working underneath an inadequately supported vehicle; or
anything exposing you to moving traffic.
YouTube is not a roadside mechanical qualification.
NEVER CRAWL UNDER AN UNSUPPORTED VEHICLE
Air suspension can move.
Vehicles can roll.
Components can fail.
Trailers can move.
Jacks can fail.
Never put yourself beneath a vehicle or trailer unless it has been safely secured and supported using the correct equipment and procedures and you are competent and authorised to be there.
WHAT IF THE OFFICE SAYS “JUST DRIVE IT BACK”?
This is one of the situations new drivers can find particularly difficult.
You report a defect.
Someone says:
“It's only ten miles.”
“Just bring it home.”
“It's been like that all week.”
“The other driver drove it yesterday.”
“It'll be grand.”
None of those statements establishes that the vehicle is safe or roadworthy.
YOU ARE THE PERSON DRIVING IT
If you genuinely believe a vehicle is unsafe, explain your concern clearly.
For example:
“I've reported the defect. I'm not satisfied that the vehicle is safe to drive until it has been assessed.”
Where appropriate:
photograph the defect;
record it through the defect system;
communicate in writing;
contact the transport manager/fleet manager/workshop; and
request competent assessment.
Stay calm.
Stay factual.
Don't turn it into an argument.
The issue is not:
“I don't want to drive it.”
The issue is:
“I do not believe it is safe to drive.”
“BUT EVERYONE ELSE DRIVES IT.”
That doesn't make the defect disappear.
Neither does:
being busy;
having no spare vehicle;
a customer waiting;
being short of drivers;
being nearly back at base; or
somebody senior becoming annoyed.
Commercial inconvenience does not repair a safety-critical defect.
DON'T SIGN FOR SOMETHING THAT ISN'T TRUE
Do not record a vehicle as defect-free if you know it isn't.
Do not mark a defect as repaired if you do not know that it has been repaired.
Do not delete or alter a genuine defect simply because somebody finds the paperwork inconvenient.
Accurate records protect:
you;
the operator;
the maintenance system; and
other road users.
AFTER A REPAIR
Where a defect has been repaired, the company's maintenance/defect system should properly record the action taken.
As the driver, satisfy yourself that the vehicle is safe before continuing.
For example, if a failed light has been repaired:
check that it now works.
If a tyre has been replaced:
include it in your check before moving.
A mechanic saying “sorted” doesn't mean you stop being the driver.
IF SOMETHING FEELS WRONG
Sometimes the first indication of a defect isn't a warning light.
It's the driver thinking:
“That doesn't feel right.”
You may notice:
steering feels different;
unusual vibration;
braking feels different;
new noise;
unusual smell;
vehicle pulling;
trailer behaving differently;
reduced power;
abnormal air-system activity; or
a change you cannot explain.
Do not dismiss your own observation simply because you cannot diagnose it.
Your job is not necessarily to know why it feels wrong.
Your job is to recognise that something has changed and act appropriately.
QUICK DEFECT DECISION
SOMETHING IS WRONG.
1. CAN I CONTROL THE VEHICLE SAFELY?
If no:
STOP AS SOON AS IT IS SAFE.
2. IS IT SAFETY-CRITICAL?
Think:
brakes;
steering;
tyres;
wheels;
coupling;
air pressure;
major suspension issue;
fire/smoke;
serious fluid leak;
insecure body/load.
If yes or possibly:
DO NOT SIMPLY CONTINUE.
3. DO I KNOW WHAT THE WARNING MEANS?
If no:
FIND OUT.
4. HAVE I REPORTED IT?
If no:
REPORT IT.
5. HAS IT BEEN RECORDED?
If required:
RECORD IT.
6. HAS A COMPETENT PERSON ASSESSED IT WHERE NECESSARY?
If no:
GET IT ASSESSED.
7. AM I SATISFIED IT IS SAFE TO CONTINUE?
If no:
DON'T DRIVE IT.
BREAKDOWN KIT — USEFUL THINGS TO HAVE
Your employer/operator may specify what is carried, but useful items can include:
hi-vis clothing;
charged phone;
charging cable/power bank;
torch;
emergency contact details;
breakdown/recovery details;
vehicle/fleet information;
first-aid equipment;
appropriate PPE;
water;
weather-appropriate clothing; and
any specialist equipment required for your operation.
Know where these things are before you need them.
REMEMBER
You do not have to diagnose every defect.
You do not have to repair every defect.
You do not have to crawl underneath the vehicle.
You do not have to change an HGV tyre at the roadside.
You do not have to continue because the office says it's “probably fine.”
You do not have to risk yourself to save a delivery.
But you do need to:
pay attention;
carry out proper checks;
recognise when something has changed;
report defects;
record them correctly;
seek competent advice; and
stop when continuing would be unsafe.
The best professional drivers aren't the ones who can somehow keep a broken vehicle moving.
They're the ones who know when it shouldn't move at all.
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