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Perform efficient truck inspections and prove the roadworthiness of your heavy vehicles with a checklist.
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Published 3 Sept 2025
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5 min read
Truck inspection checklists or heavy vehicle inspection checklists are tools used to check trucks for roadworthiness and ensure that all parts of your truck fleet are equipped to pass annual regulatory and DOT inspections.
A truck inspection, also known as DOT inspection or DOT truck inspection, is conducted by the Department of Transportation, requiring all commercial motor vehicles (CMV) weighing more than 10,000 pounds to be evaluated in order to ensure that vehicle parts and accessories are safe and in good working condition. Meeting the truck inspection requirements of the U.S. Department of Transportation (DOT) and similar agencies maintains the excellent performance and safety of these heavy vehicles.
The following items and areas are checked using a DOT inspection checklist during routine truck inspections:
Brake System
Steering System
Windshields
Wipers
Fuel System
Lighting Devices
Coupling Devices
Exhaust System
Safe Loading
Suspension
Frame
Tires
Wheels and Rims
Cargo and Equipment
Safety
Trailer
More details on this truck inspection checklist that you can view and download for free. Also available in PDF.
Using a comprehensive checklist while conducting a truck inspection allows for a streamlined process where the users can always follow a standard, and help them avoid missing areas of inspection. A truck inspection checklist would ideally include these steps :
Specify vehicle information – Input initial data such as vehicle type, vehicle identification type, license plate, model, and mileage. Attach a photo of the vehicle as well for visual reference.
Inspect vehicle parts individually – Completely go through the listed areas of vehicle parts to be checked. Make sure that you’re not missing anything and that the inspection is done in a detailed and factual manner.
Indicate the status of inspected vehicle parts – Emphasize the condition of the vehicle and highlight if there are parts that need repair. Choose between OK, Needs Repair, Repaired, or N/A, or customize the options according to your business needs.
Rate overall vehicle condition – Provide a summary by adding any other points that may affect the vehicle’s safe operation. Rate its overall condition by selecting from choices such as excellent, good, average, poor, and high risk.
Add recommendations – Before completing the inspection with a signature, enter any recommendations that can improve the vehicle condition, if any.
Heavy Vehicle Inspection Checklist Sample Report | SafetyCulture
Most commercial motor vehicles (CMVs) weighing over 10,000 pounds have to undergo an annual DOT inspection. These inspections are carried out by qualified DOT inspectors who check that all CMVs on the road are safe and in good working condition and that the business has proper recordkeeping processes in place. A DOT inspection consists of 6 levels which are:
During level 1, the inspector checks important documents such as:
the vehicle operator’s license;
medical certificate of their annual DOT physical exam;
service record of the last 8 on-duty days; and
medical card or waiver (if any).
The inspector will also check if the vehicle operator is under the influence of drugs, alcohol, or any other hazardous material.
This level involves getting under the vehicle to check other parts of the vehicle that weren’t examined during the first level.
During this inspection, the inspector takes a closer examination of the vehicle operator’s credentials, such as:
License;
Endorsements;
Skill Performance Evaluation certificate
Vehicle inspection reports
Other inspection items include seatbelt usage and signs of drug and/or alcohol use.
Level 4 is a one-time inspection that examines a specific item. It is scheduled to validate or invalidate a claim about a vehicle.
This level of inspection inspects vehicle parts that were specified under level 1. Its difference with level 1 is that this is conducted without the presence of the driver.
This level is for vehicles hauling radioactive freight. The vehicle, cargo, and driver must pass the inspection before leaving for delivery. Once all criteria are met, a special decal is given as verification of passing the inspection. The decal, however, is only valid for one trip and will be removed upon reaching the delivery point.
Requirements for inspecting heavy vehicles may vary between states and countries, but the underlying principle remains the same: ensure the roadworthiness of these vehicles. Here’s a quick overview of the truck inspection requirements in select countries:
Operators must perform regular roadworthiness checks according to the HGV inspection manual. The Driver and Vehicle Standards Agency (DVSA) requires daily walkaround checks by drivers and periodic safety inspections as part of vehicle maintenance.
Heavy vehicle operators must conduct periodic inspections to ensure safety and roadworthiness, with reports submitted during roadside checks. Roadside inspections are also performed on the spot to assess the vehicle’s condition and environmental compliance.
Under the Heavy Vehicle National Law (HVNL), vehicles over 4.5 tons must meet national safety and emissions standards. Inspectors follow the National Heavy Inspection Manual and local authority guidelines for vehicle assessments.
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