Safety Compliance Testing for FMVSS 121 - CarsAndRacingStuff.com

SAFETY COMPLIANCE TESTING FOR FMVSS 121Air Brake SystemsVehicle: MY 2007 TEBCO TG (6X4) Dump Truck21-ft./23-yd. Dump BodyTebco of Kentucky Inc.Report #: 121V-TRC-06-007NHTSA #: C70701TRC Inc. Test #: 20040769/7005Transportation Research Center Inc.P. O. Box B-67East Liberty, Ohio 43319-0367June 2007Final ReportU.S. Department of TransportationNational Highway Traffic Safety AdministrationEnforcementOffice of Vehicle Safety ComplianceWest Building, W45-1171200 New Jersey Avenue, S.E.Washington, D.C. 20590

1. REPORT NUMBER:2. GOVERNMENT ACCESSION NO.: 3. RECIPIENTS CATALOG NO.:121V-TRC-06-0074. TITLE AND SUBTITLE:5. REPORT DATE:Final report of FMVSS 121 Compliance Testing of aJune 20, 20072007 TEBCO TG (6X4) Dump Truck, NHTSA No. C70701 6. PERFORMING ORGANIZATION CODE:TRC 20040769/70057. AUTHOR(S): Project Manager: RANDALL A. LANDES 8. PERFORMING ORGANIZATION REPORT NO.:9. PERFORMING ORGANIZATION NAME AND ADDRESS:Transportation Research Center Inc.10820 State Route 347East Liberty, Ohio 4331912. SPONSORING AGENCY NAME AND ADDRESS:U.S. Department of TransportationNational Highway Traffic Safety AdministrationEnforcementOffice of Vehicle Safety ComplianceWest Building, W45-1171200 New Jersey Ave., S.E.Washington, DC 2059015. SUPPLEMENTARY NOTES:121V-TRC-06-00710. WORK UNIT NUMBER:11. CONTRACT OR GRANT NO.:DTNH22-05-C-0100613. TYPE OF REPORT AND PERIOD COVERED:Final test reportTested: 04/22/07 to 06/15/0714. SPONSORING AGENCY CODE:NVS-22016. ABSTRACT:Compliance tests were conducted on the subject 2007 TEBCO TG (6X4) Dump Truck, NHTSA No. C70701, in accordance with the specifications of the Office of VehicleSafety Compliance Test Procedure No. TP-121V-05, for the determination of FMVSS 121 compliance.Test failures identified were as follows:None.17. KEY WORDS: Compliance TestingSafety EngineeringFMVSS 12118. DISTRIBUTION STATEMENT:Copies of this report are available from:NHTSA Technical Information Services (TIS), Rm. 5108Nassif Building, Room 5108 (NPO-230)400 Seventh Street, SW,Washington, DC 20590Telephone No. (202) 366-494919. SECURITY CLASSIF. (OF THISREPORT):Unclassified20. SECURITY CLASSIF. (OF THISPAGE).Unclassified21. NO. OF PAGES: 85 22. PRICE:ii20040769/7005

Table of ContentsSection Description Page1.0 Purpose of Compliance Test 12.0 Vehicle Information 43.0 Test Data Summary 64.0 Test Data 85.0 Instrumentation List 31Appendix AAppendix BAppendix CPhotographsTest Data from Report GeneratorContractor’s Test Commentsiii20040769/7005

List of Tables/Data SheetsNo. TitlePageTest Data Summary1. Summary of Data for Laboratory Test “Application & Release Times” 72. Data Summary of the Stopping Distances 7Test Data3. Vehicle Information Sheet - FMVSS 121 94. Verification of Required Equipment 13Laboratory Tests5. Brake Actuation and Release Times 14Road Tests6. Park Brake Chamber Actuation Pressure 1510. Burnish 1611. Service Brake Stopping Test - GVWR 1912. Emergency Brake Stopping Test- Primary Reservoir Failure @ GVWR 2013. Emergency Brake Stopping Test- Secondary Reservoir Failure @ GVWR 2114. Emergency Brake Stopping Test- Primary Control Line Failure @ GVWR 2215. Park Brake Test, 20% Grade Holding - GVWR 2317. Stability and Control - LLVW 2418. Service Brake Stopping Test - LLVW 2519. Emergency Brake Stopping Test - Primary Reservoir Failure @ LLVW 2620. Emergency Brake Stopping Test - Secondary Reservoir Failure @ LLVW 2721. Emergency Brake Stopping Test - Primary Control Line Failure @ LLVW 2822. Park Brake Test, 20% Grade Holding – LLVW 2923. Final Inspection 30iv20040769/7005

FigureLIST OF PHOTOGRAPHSPhotograph Title1. Front View @ GVWR2. Right Side View @ GVWR3. Left Side View @ GVWR4. Rear View @ GVWR5. Front View @ LLVW6. Right Side View @ LLVW7. Left Side View @ LLVW8. Rear View @ LLVW9. Final Stage Manufacturer’s Placard10. Incomplete Vehicle Manufacturer’s Placard11. Body Manufacturer’s Placard12. Wet/Supply & Secondary (Top) and Primary (Bottom) Reservoirs13. Left Front/Steer Brake Assembly14. Left Front/Steer Brake Chamber15. Left/Front Steer Brake Slack Adjuster16. Left/Front Steer Brake Thermocouple Installation17. Left and Right/Front Steer Brake ABS Modulators/Quick Release Valve18. Left/Front Steer Brake ABS Wheel Speed Sensor19. Right Intermediate Drive Axle Brake Assembly20. Right Intermediate Drive Axle Brake Chamber21. Right Intermediate Drive Axle Brake Slack Adjuster22. Right Intermediate Drive Axle Brake Thermocouple Installation23. Right Rear Drive Axle Brake Assembly24. Right Rear Drive Axle Brake Chamber25. Right Rear Drive Axle Brake Slack Adjuster26. Right Rear Drive Axle Brake Thermocouple Installation27. Right Tandem Drive Axle Brakes ABS Modulator28. Right Rear Drive Axle Brake ABS Wheel Speed Sensor29. Rear Brakes R12 Valvev20040769/7005

LIST OF PHOTOGRAPHS, CONTINUED30. Rear Brakes Parking Brake Valve31. Air Dryer32. Instrumentation in Vehicle33. Ballast in Vehicle34. Ballast in Vehicle35. Dash Warning Lampsvi20040769/7005

Section 1.0Purpose of Compliance Test120040769/7005

PurposeTransportation Research Center Inc. (TRC Inc.) conducted this program for the NationalHighway Traffic Safety Administration (NHTSA). The purpose of this test was to determine ifthe subject vehicle, a 2007 TEBCO TG (6X4) dump truck, meets the performance requirementsof FMVSS 121, “Air Brake Systems.”220040769/7005

Test ProcedureThis test was conducted in accordance with NHTSA’s Office of Vehicle Safety Compliance(OVSC) Laboratory Test Procedure No. TP-121V-05. Data was obtained relative to FMVSS121, “Air Brake Systems.” Deviations from the procedure: The only tests performed undersection 10.2 “Laboratory Tests” were 10.2 I. “Brake Actuation and Release Timing.” The testsequence was performed as follows:1. Burnish GVWR2. Brake Actuation and Release Timing GVWR3. Service Brake Stops GVWR4. Emergency Brake (Primary Reservoir Failure) Stops GVWR5. Emergency Brake (Secondary Reservoir Failure) Stops GVWR6. Emergency Brake (Primary Control Line Failure) Stops GVWR7. Park Brake – Grade Holding GVWR8. Stability & Control LLVW9. Service Brake Stops LLVW10. Emergency Brake (Primary Reservoir Failure) Stops LLVW11. Emergency Brake (Secondary Reservoir Failure) Stops LLVW12. Emergency Brake (Primary Control Line Failure) Stops LLVW13. Park Brake – Grade Holding LLVW14. Final InspectionThe vehicle information is summarized in Section 2.0. The test data summary is located inSection 3.0, the test data is located in Section 4.0, and the test summary is located in Section 5.0.Appendix A contains the still photographic prints. The Appendix lists the test data in ReportGenerator format.320040769/7005

Section 2.0Vehicle Information420040769/7005

Vehicle InformationThe completed test vehicle is a 2007 TEBCO TG (6X4) Dump Truck, and the incompletevehicle (cab/chassis) was a model CV713 Granite, manufactured by Mack Trucks, Inc. with awheelbase of 276 inches. The Gross Vehicle Weight Rating (GVWR) is 62,000 pounds and thetest vehicle is equipped with a Bendix KB, 4S/4M anti-lock brake system.520040769/7005

Section 3.0Test Data Summary620040769/7005

Test Data SummaryTable 1Summary of Data for Laboratory Test “Application & Release Times”AverageTimes inSecondsFull SystemOperatingABS MainPower FailedABS WheelSensor Failed(Open)Application Max.Allowable – 0.45LeftSteer#1LeftDrive#2LeftDrive#3LeftSteer#1Release Max.Allowable – 0.55LeftDrive#2LeftDrive#30.362 0.415 0.411 0.399 0.539 0.5380.361 0.411 0.407 0.403 0.532 0.5320.360 0.415 0.410 0.402 0.537 0.537ABS Wheel 0.356 0.412 0.406 0.414 0.546 0.544Sensor Failed(Short)The nominal park brake chamber pressures were 0 psi, 3 seconds after control valve actuated.Table 2Data Summary of the Stopping DistancesDistance in Feet(Corrected Dist.)GVWR LLVW MaximumAllowableMinimum Maximum Minimum Maximum (ft.)1.2 Service Brakes 283.5 333.1 194.1 210.4 GVWR – 310LLVW – 335Failed PrimaryReservoir365.2 434.1 210.4 232.6 GVWR – 613LLVW – 613Failed Secondary 348.1 388.7 256.8 279.3 GVWR – 613ReservoirFailed PrimaryControl LineLLVW – 613399.3 422.0 219.6 242.8 GVWR – 613LLVW – 613The vehicle passed the Stability and Control tests. For the vehicle type, only the LLVW masscondition is required.720040769/7005

Section 4.0Test Data820040769/7005

TEST DATATABLE 3VEHICLE INFORMATION SHEET - FMVSS 121Vehicle: 2007 TEBCO TG (6x4) Dump TruckVeh. Number: C70701Test No.: 20040769/7005 Test Date(s): 04/22/2007 to 06/04/07Test Facility/Location: TRC/Transportation Research Center Inc., East Liberty, OhioTruck/Tractor Year, Make, and Model: 2007 Tebco Kentucky, TG Series, 6X4,21-Ft. /23-Yd. Dump Body TruckBuild Date: 05/06Body No.: 0605002VIN: 1M2AG11CX7M063068Chassis No.: No DataGVWR: 62,000 lbs. GAWRs: 18,000 lbs. – Steer: 44,000 lbs. – Drives (total)Engine Data: Type: (Diesel, gas, other) DieselI-6 Cylinders 728 Cu. In. NA Liter 335 HPTransmission: 8 Speed X Manual Automatic O.D.Axle Drive Configuration: 6X4Center of Gravity (in): 51 (Estimated)Initial Odometer:545 mi.Wheelbase: Truck, (in): 276Control Trailer, (in): N/ARetarder(s) Type(s): One-Engine (Mack) Aerodynamic Treatments: Yes No XBRAKES:Type 1 Size Make Lining (Edge Code)Axles:Steer #1 Cam 15 x 6 in. Meritor R301 FFDrive #2 Cam 16.5 x 7 in. Meritor R301 FFDrive #3 Cam 16.5 x 7 in. Meritor R301 FF1 Cam, disc, wedge, etc.920040769/7005

....ContinuedBRAKE DRUM/ROTOR:Type 2 Make Dust Shields Installed?Axles:Steer #1 Cast Drum Gunite YesDrive #2 Cast Drum Gunite YesDrive #3 Cast Drum Gunite Yes2 Cast or composite drum, vented or non-vented rotor, etc.ACTUATION DETAILS:AIR CHAMBERSSLACK ADJUSTERSLength orMake Type 3 Wedge angle Mfr. CamRotation 4Axles:Steer #1 MGM T24 5.5 in. Haldex SameDrive #2 MGM T30/30 6.0 in. Haldex SameDrive #3 MGM T30/30 6.0 in. Haldex Same3 Size and diaphragm or piston4 Same or opposite to forward wheel rotationTIRESStatic Loaded RadiusPressure (psi) Size Make Model Measured* Databook(Website)Axles:Steer #1 120 psi 425/65R22.5 Goodyear G286 20.1 in. 20.3 in.Drive #2 105 psi 11R22.5 Goodyear G164 RTD 19.2 in. 19.5 in.Drive #3 105 psi 11R22.5 Goodyear G164 RTD 19.2 in. 19.5 in.*Measured at test GVWR.REMARKS: There were dual tires at each wheel end on the rear drive axles, only.1020040769/7005

....ContinuedABS:Mfr: Bendix KB* Model: (Part #) 96-01-22* Configuration: 4S/4MFRONT SUSPENSION:Type: Solid Axle/Taper Leaf Spring Make: Mack Model: 0610930MnB580INTERMEDIATE (TAG) SUSPENSION:Type: Solid Axle/Trunnion Leaf Spring Make: Mack* Model: S440*REAR SUSPENSION:Type: Solid Axle/Trunnion Leaf Spring Make: Mack* Model: S440*Rear Axle Spread, (in): 55 Overall Width (SAE J693): 97 in.FIFTH WHEEL:Fifth Wheel Height Relative to Ground (in): N/AFifth Wheel Position, (in): N/AAIR SYSTEM:Compressor Capacity (cfm): 18.7*Cut-out (psi): No DataCut-in (psi): No DataCrack Pressure Ratings (psi) 5 :1st Axle: No Data 2nd Axle: No Data Treadle Valve 6 : No Data5 Relative to rear axle(s) centerline (include sketch if necessary)6 Total crack pressures between treadle valve and brake chambersFront Axle Limiting:No DataAir Dryer: Meritor 1200P*Air Compounding:Number of Brakes Controlled:No DataSix brake positions ABS controlled, (4S/4M).*Manufacturer’s data.1120040769/7005

....ContinuedAIR TANK VOLUMES. (cu. in.):Supply: No Data Primary: No Data Secondary: No DataAuxiliary: No DataIsolated From Service? No DataNote: None.SPECIAL CONDITIONS:None.WEIGHTS (lbs):Empty LLVW Burnish GVWR GAWRAxle:Steer #1 11,740 12,100 18,030 18,030 18,000Drive #2 7,020 7,130 22,030 22,030 22,000Drive #3 7,010 7,040 21,920 21,920 22,000Total: 25,770 26,270 61,980 61,980 62,000REMARKS:Placard GVWR: 62,000 lbs.1220040769/7005

TEST DATATABLE 4VERIFICATION OF REQUIRED EQUIPMENTVehicle: 2007 TEBCO TG (6X4) Dump TruckVeh. No.: C70701Date: 05-07-07 Driver: R. Herberling Technician: R. Landes Odometer: 595 mi.SERVICE BRAKES YES NOAll Wheels Equipped with BrakesAll Brakes Equipped with Automatic Brake AdjustersXXBrake Adjustment Indicators are visible from a locationadjacent to or beneath the vehicleANTILOCK BRAKE SYSTEMAntilock System InstalledProper axle controlXXXComments:NoneAntilock Warning Signal within Drivers Field-of-ViewAmber letters, black background, no audible warningXSERVICE RESERVOIRSNo. of Reservoirs 3Automatic Condensate drain valve(s) or supply reservoirXAutomatic Operation of condensate drain valveXEach Reservoir has a Drain Valve which can be manuallyoperatedPARKING BRAKESParking Brake Control Separate from Service Brake ControlParking Brake Control Accessible from Operator’s SeatParking Brake control is identified in a mannerthat specifies its operationXXXXParking Brake Control Operates Parking Brakesof Towed Vehicle N/A Yes X NoREMARKS: None.1320040769/7005

LABORATORY TESTSTABLE 5BRAKE ACTUATION AND RELEASE TIMESVehicle: 2007 TEBCO TG (6X4) Dump TruckVeh. Number: C70701Date: 02-26-07 Driver: R. Landes Technician: R. LandesFULL SYSTEM - ABS MAIN POWER ACTIVERunNo.Left Steer #1 Left Drive #2 Left Drive #3Apply(sec)Release(sec)Apply(sec)Release(sec)Apply(sec)Release(sec)1 0.363 0.397 0.414 0.535 0.410 0.5342 0.361 0.390 0.416 0.533 0.411 0.5323 0.363 0.409 0.416 0.529 0.411 0.529Avg. 0.362 0.399 0.415 0.532 0.411 0.532FULL SYSTEM - ABS MAIN POWER FAILED1 0.365 0.401 0.411 0.553 0.408 0.5332 0.358 0.389 0.410 0.529 0.404 0.5293 0.359 0.419 0.412 0.536 0.408 0.534Avg. 0.361 0.403 0.411 0.539 0.407 0.538ABS - WHEEL SENSOR FAILED – OPEN1 0.363 0.401 0.416 0.535 0.412 0.5342 0.359 0.408 0.414 0.534 0.409 0.5343 0.359 0.398 0.414 0.546 0.410 0.546Avg. 0.360 0.402 0.415 0.537 0.410 0.539ABS - WHEEL SENSOR FAILED – SHORT1 0.359 0.399 0.412 0.544 0.408 0.5402 0.353 0.414 0.410 0.555 0.404 0.5553 0.356 0.420 0.413 0.538 0.407 0.538Avg. 0.356 0.412 0.296 0.546 0.406 0.544REMARKS: To simulate the “Open” failure and immediately adjacent to the wheel, theright steer axle #1 wheel speed sensor lead was disconnected. To simulate the“Shorted” failure and immediately adjacent to the wheel, the right steer axle #1 wheelspeed sensor connector was disconnected and the two receptacle wire ends to the ABSECU were connected with a wire. For the ABS Active tests, the ignition was in theON/RUN position with the engine not running. For the ABS Main Power Failed tests,the ignition was in the OFF position. All tests were performed with the vehicle attachedto “shop” air and regulated to approximately 100 psi.1420040769/7005

ROAD TESTSTABLE 6PARK BRAKE CHAMBER ACTUATION PRESSUREPARKING BRAKE TESTVehicle: 2007 TEBCO TG (6X4) Dump TruckVehicle Number: C70701Test Performed By: R. Landes Date: 05-25-07PARK BRAKE CHAMBER ACTUATION PRESSURERUNNUMBERAXLE # 2PRESSURE IN INTERMEDIATE PARKING CHAMBER AFTER 3SECONDS (PSI)LEFTRIGHT1 0 02 0 03 0 0AVERAGE 0 0RUNNUMBERAXLE # 3PRESSURE IN INTERMEDIATE PARKING CHAMBER AFTER 3SECONDS (PSI)LEFTRIGHT1 0 02 0 03 0 0AVERAGE 0 0If average pressure is less than or equal to 3 psi, use 0 psiREMARKS: Average time to reach 3 psi – 1.75 sec. for #2; 2.05 sec. for #3.Note: Tables 7 through 9 are for tests not performed by the laboratory and are,therefore, not included.1520040769/7005

ROAD TESTSTABLE 10BURNISHVehicle: 2007 TEBCO TG (6X4) Dump TruckVehicle Number: C707018.1 BURNISH TEST WEIGHT STEER AXLES: 18,030 lbs DRIVE/TAG AXLES: 43,950 lbsDriver No. Date Odometer Start Odometer End1 05/14/07 609 7041 05/15/07 704 9061 05/16/07 906 1131Date Time OdometerTest Start 05/14/07 16:35 609Test Finish 05/16/07 23:45 1131ADJUSTMENT LEVELS1L 1R 2L 2R 3L 3R 4L 4RInitial 5/8 in. 5/8 in. 5/8 in. 5/8 in. 5/8 in. 5/8 in. NA NA1st NA NA NA NA NA NA NA NA2nd 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. 1/2 in. NA NA3rd 1/2 in. 1/2 in. 1/2 in. 1/2 in. NA NA NA NAFinal 1/2 in. 1/2 in. 1/2 in. 5/8 in. 5/8 in. 1/2 in. NA NAREMARKS: A mechanic adjusted the freestrokes to 5/8 in. measurement. “Freestroke”measurement values were checked and if less than 1/2 in., adjusted to at least 1/2 in. atthe required intervals and at brake temperatures below 200 degrees F. All initialBurnish adjustment clearances were set at 5/8 in.All post-Burnish adjustments set to 5/8 in. freestroke.At snub #125, the driver determined the temperatures and balance were nominal, andtherefore, did not adjust.Driver #1 – Richard Heberling.1620040769/7005

....ContinuedSnub#InitialSpeed(mph)Avg.Cntrl.Press.(psi)Avg.Decel(ft/s 2 )1L 1R 2L 2R 3L 3R1 40.3 53 8.5 131 123 143 142 157 15625 40.6 98 10.3 396 383 443 441 480 46150 40.6 75 10.4 353 336 521 561 561 56875 40.4 74 10.2 349 332 539 573 577 598100 40.5 62 10.2 315 300 337 369 360 349125 40.6 67 10.8 370 354 481 513 519 516150 40.5 59 9.9 364 346 495 519 541 540175 40.8 56 9.9 366 347 492 514 545 536200 40.0 58 9.7 362 346 465 487 504 500225 40.2 60 10.2 373 356 481 504 530 521250 40.4 60 10.5 368 349 503 525 546 534275 40.2 59 10.2 352 336 496 521 542 527300 40.1 56 10.0 298 275 380 414 414 398325 40.0 48 9.4 351 323 502 524 554 530350 40.3 52 9.6 339 306 514 524 569 540375 40.6 54 10.0 351 325 543 546 597 565400 40.5 55 10.6 329 296 468 493 526 498425 40.5 58 10.4 360 328 549 560 600 571450 40.4 53 9.7 342 310 543 547 595 570475 39.4 62 10.9 344 308 537 544 591 568500 39.6 57 10.2 345 317 543 545 599 579(Table continued on next page)Initial Brake Temperatures ºFREMARKS: #1 = steer axle; #2 = forward or intermediate drive axle; #3 = rear driveaxle.1720040769/7005

....ContinuedSnub #InitialTargetSpeedmphAmbientTemp ºFCommentsDriverInitialsTime1 40 79 Initiate. RH 16:3525 40 80 RH50 40 81 RH75 40 81 Break/fuel @ #77. RH 18:50100 40 84 *Engine off/stopped @ #88. RH 21:00125 40 83 RH150 40 83 RH175 40 83 RH200 40 82 RH225 40 81 RH250 40 79 Check adjust/break. RH 20:50275 40 72 End shift @ #282. RH 22:35300 40 54 RH325 40 54 RH350 40 55 RH375 40 55 Check adjust/break. RH 18:50400 40 55 RH425 40 53 RH450 40 51 RH475 40 50 RH500 40 48 Burnish complete. RH 11:45REMARKS: *The engine would not continue to operate – would shut off automatically.The serpentine drive belt for the water pump had failed. The rental agency sent atechnician with a new belt and repaired it the following morning. No further serpentinebelt issues were encountered.1820040769/7005

DATA SHEET 11SERVICE BRAKE STOPPING TEST @ GVWRVehicle:_ 2007 TEBCO TG (6X4) Dump Truck _TRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,147_/ 1,174____Date:__05/18/07__ Driver:_R. Heberling Tech./Video: R. Landes_____Project/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Time:_13:10 – 15:30_____IBTs: 150° to 200°F.Requirements: Air system fully charged before each stop.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Manual brake adjustments permitted prior to performing stops.Brake Stroke Measurements @ 85 psi (in) “Free” Stroke Measurements (in.)Axle 1 Left/Right 1 1/2 / _1 1/2 Axle 1 Left/Right 5/8 / __5/8___Axle 2 Left/Right 1 3/4 / _1 3/4 Axle 2 Left/Right 5/8 / __5/8___Axle 3 Left/Right 1 3/4 / _1 3/4 Axle 3 Left/Right 5/8 / __5/8___Axle 4 Left/Right NA / _NA Axle 4 Left/Right NA / __NA___Dist. Req. (ft.) @ 60: GVW&LLVW Bus: 280; GVW Truck: 310; LLVW Truck & Tractor: 335; GVWR Tractor: 355.StopApplicationPressure(psi)60 MPH SERVICE BRAKE STOPS - GVWRActual CorrectedStopping Stopping InDistance Distance 12 foot(feet) per SAE Lane?J299InitialSpeed(mph)Wheel LockupIndicationPosition, Spd.(mph), Timelocked (sec.)Comments1 112.6 60.1 334.6 331.1 Yes No Video Tape2 113.4 58.8 301.4 314.3 Yes No Video Tape3 121.7 60.3 286.5 283.5 Yes No Video Tape4 118.0 60.6 316.0 310.1 Yes No Video Tape5 107.3 60.4 305.7 301.4 Yes No None*6 118.1 20.3 36.8 35.7 Yes No Video TapeAmbient Temp.: 61°F Wind Speed/Dir.: 7 mph, 353° NComments: *Not required – indicant test, only.1920040769/7005

DATA SHEET 12EMERGENCY BRAKE STOPPING TESTPRIMARY RESERVOIR FAILURE @ GVWRVehicle:__ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,198 / 1,219____Date:_05/21/07__ Driver:_R. Herberling Tech./Video:_K. Easterday______Project/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Requirements: Air system fully charged before each stop.Time:_10:30 – 12:50____IBTs: 150° to 200°F.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake between three and five seconds after warning displayed.Dist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.Stop60 MPH EMERGENCY BRAKE STOPS - GVWR (Primary Reservoir)ApplicationPressure(psi)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEJ299In12 footLane?Wheel LockupIndicationPosition, Spd.(mph), Timelocked (sec.)Comments1 54.0 59.9 418.6 419.5 Yes No Video Tape2 54.2 59.9 425.1 426.9 Yes No Video Tape3 48.2 59.9 364.2 365.2 Yes No None4 51.7 59.6 427.6 434.1 Yes No None5 52.7 59.8 395.3 398.1 Yes No None6* 42.6 20.2 49.2 48.2 Yes No Video TapeAmbient Temp.: 64°F Wind Speed/Dir.: 4 mph, 158° SEComments: *Not required – indicant test, only.2020040769/7005

DATA SHEET 13EMERGENCY BRAKE STOPPING TESTSECONDARY RESERVOIR FAILURE @ GVWRVehicle:___ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,221 / 1,239___Date:__05/21/07__ Driver:__R. Heberling Tech./Video:__ R. LandesProject/Segment Nos.:___20040769/7005___Time:_13:45 – 15:15___Ambient Temperature: 32° to 100°F.IBTs: 150° to 200°F.Requirements: Air system fully charged before each stop.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake between three and five seconds after warning displayed.Dist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.Stop60 MPH EMERGENCY BRAKE STOPS - GVWR (Secondary Reservoir)ApplicationPressure(psi)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEJ299In12 footLane?Wheel LockupIndicationPosition, Spd.(mph), Timelocked (sec.)Comments1 91.3 60.7 397.1 388.7 Yes No Video Tape2 95.5 60.7 376.8 368.6 Yes No Video Tape3 99.7 59.8 382.1 384.3 Yes No None4 101.2 59.7 344.9 348.1 Yes No None5 96.8 60.4 366.1 361.1 Yes No None6* 106.2 20.6 40.2 37.9 Yes No Video TapeAmbient Temp.: 76°F Wind Speed/Dir.: 10 mph, 133° SEComments: *Not required – indicant test, only.2120040769/7005

DATA SHEET 14EMERGENCY BRAKE STOPPING TESTPRIMARY CONTROL LINE FAILURE @ GVWRVehicle:___ 2007 TEBCO TG (6X4) Dump Truck __TRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,269 / 1,302____Date:__05/22/07__ Driver:__R. Heberling Tech./Video:__ R. Landes _Project/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Requirements: Air system fully charged before each stop.Time:_12:55_- 16:00_IBTs: 150° to 200°F.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake any time after opening solenoid.Dist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.60 MPH EMERGENCY BRAKE STOPS - GVWR (Primary Control Line)StopApplicationPressure(psi)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEIn12 footLane?Wheel LockupIndicationPosition, Spd. CommentsJ299(mph), Timelocked (sec.)1 88.4 60.2 424.1 422.0 Yes No Video Tape2 87.9 60.0 412.5 412.3 Yes No Video Tape3 85.6 60.4 409.1 403.9 Yes No None4 92.4 60.3 403.9 399.3 Yes No None5 84.3 60.1 416.8 415.4 Yes No None6* 93.3 20.8 59.2 54.7 Yes No Video TapeAmbient Temp.: 81°F Wind Speed/Dir.: 10 mph, 143° SEComments: *Not required – indicant test, only.2220040769/7005

ROAD TESTSDATA SHEET 15PARK BRAKE TEST20% GRADE HOLDING - GVWRVehicle:___ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,310___Date:__05/23/07_ Driver:_R. Heberling Tech./Video:_K. Easterday/S. WagonerProject/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Parking Brake Chamber(s) Pressure 0 psiTime:_9:15_- 9:25___IBT’s: 150° to 200°F.20% GRADE HOLDING - GVWRX GVWRLLVWInitial BrakeTemperature(s)(ºF)Hottest BrakeControlPressure toHold Vehicle(psi)Movement toBecomeStationary onGrade(inches)Stationary on GradeFor 5 minutesYesNoUp Grade* 168 34 0 XDown Grade 172 34 0 XAmbient Temp.: 70°FWind Speed:Direction:5 mph158° SEREMARKS: The test vehicle remained stationary on the grade facing upgrade anddowngrade for the required 5-minute period. Therefore, Static Retardation Force Testnot required. Both directions were video taped.Note: Static Retardation Force @ GVWR was not required; therefore, Data Sheet 16 isnot included.2320040769/7005

ROAD TESTSDATA SHEET 17STABILITY & CONTROL @ LLVWVehicle: 2007 TEBCO TG (6X4) Dump TruckVeh. No.: C70701Initial/End Odo.:1,320 – 1,323_Date: 05-23-07 Driver: R. Herberling Observer/Video: R. LandesProject/Segment Nos.:___20040769/7005___Time:_13:30_- 13:45___Manually Controlled Retarder: NAMaximum Drive Through Speed 37 mph75% of Max Drive Through Speed 27.8 mphStopNo.InitialSpeed(mph)*ApplyTime(sec)STABILITY & CONTROL - LLVWApprox.Dist. Outof Lane (ft)NumberMarkersHitComments1 28.2 0.145 0 0 Video Tape2 27.4 0.161 0 0 Video Tape3 28.0 0.178 0 0 Video Tape4 28.0 0.174 0 0 Video TapeAmbient Temp.:Wind Speed:Direction:84° F5 mph277° WREMARKS: The vehicle remained in the lane during all four stops.* See Appendix C.2420040769/7005

DATA SHEET 18SERVICE BRAKE STOPPING TEST @ LLVWVehicle:___ 2007 TEBCO TG (6X4) Dump Truck _TRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,326 / 1,351____Date:__5/23/07_ Driver:_R. Heberling Tech./Video:_ R. LandesProject/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Time:_14:50 – 15:40_____IBTs: 150° to 200°F.Requirements: Air system fully charged before each stop.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Manual brake adjustments permitted prior to performing stops.Brake Stroke Measurements @ 85 psi (in)“Free” Stroke Measurements (in.)Axle 1 Left/Right 1 1/2 / _1 1/2 Axle 1 Left/Right 5/8 / __5/8___Axle 2 Left/Right 1 3/4 / _1 3/4 Axle 2 Left/Right 5/8 / __5/8___Axle 3 Left/Right 1 3/4 / _1 3/4 Axle 3 Left/Right 5/8 / __5/8Axle 4 Left/Right NA / _NA Axle 4 Left/Right NA / __NA _Dist. Req. (ft.) @ 60: GVW&LLVW Bus: 280; GVW Truck: 310; LLVW Truck & Tractor: 335; GVWR Tractor: 355.60 MPH SERVICE BRAKE STOPS - LLVWStopApplicationPressure(psi)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEIn12 footLane?Wheel Lock-upIndicationPosition, Spd.(mph), Time CommentsJ299locked (sec.)1 92.7 60.0 210.1 210.4 Yes NO Video Tape2 99.0 59.6 198.9 201.9 Yes NO Video Tape3 98.3 60.0 193.8 194.1 Yes NO None4 102.3 59.9 205.0 205.6 Yes NO None5 96.7 59.7 199.9 202.0 Yes NO None6* 89.8 20.3 30.0 29.1 Yes NO Video TapeAmbient Temp.: 85° F Wind Speed/Dir.: 8Comments: *Not required – indicant test, only.mph, 232° SW2520040769/7005

DATA SHEET 19EMERGENCY BRAKE STOPPING TESTPRIMARY RESERVOIR FAILURE @ LLVWVehicle:__ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,361 / 1,380____Date:__05/24/07_ Driver:__R. Heberling Tech./Video:__R. LandesProject/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Requirements: Air system fully charged before each stop.Time:_8:50 – 9:15 ____IBTs: 150° to 200°F.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake between three and five seconds after warning displayed.StopDist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.ApplicationPressure(psi)60 MPH EMERGENCY BRAKE STOPS - LLVW (Primary Reservoir)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEJ299In12 footLane?Wheel Lock-upIndicationPosition, Spd.(mph), Timelocked (sec.)Comments1 54.4 59.7 215.2 217.3 Yes NO Video Tape2 53.8 58.2 208.1 221.0 Yes NO Video Tape3 55.5 59.3 205.2 210.4 Yes NO None4 48.4 60.8 239.0 232.6 Yes NO None5 54.6 60.1 215.5 215.1 Yes NO None6 51.8 19.8 27.9 28.5 Yes NO Video TapeAmbient Temp.: 69°F Wind Speed/Dir.: 6 mph,Comments: *Not required – indicant test, only.154°SE2620040769/7005

DATA SHEET 20EMERGENCY BRAKE STOPPING TESTSECONDARY RESERVOIR FAILURE @ LLVWVehicle:__ __2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,380 / 1,401__Date:__05/24/07__ Driver:__R. Heberling Tech./Video:_ R. LandesProject/Segment Nos.:___20040769/7005___Time:__9:25_- 10:15_Ambient Temperature: 32° to 100°F.IBTs: 150° to 200°F.Requirements: Air system fully charged before each stop.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake between three and five seconds after warning displayed.StopDist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.60 MPH EMERGENCY BRAKE STOPS - LLVW (Secondary Reservoir)ApplicationPressure(psi)InitialSpeed(mph)ActualStoppingDistance(feet)CorrectedStoppingDistanceper SAEJ299In12 footLane?Wheel Lock-upIndicationPosition, Spd.(mph), Timelocked (sec.)Comments1 102.2 59.0 267.2 276.5 Yes NO Video Tape2 98.6 60.5 283.2 278.3 Yes NO Video Tape3 93.7 59.8 277.6 279.3 Yes NO None4 94.2 61.1 266.5 256.8 Yes NO None5 97.9 59.8 268.8 270.9 Yes NO None6* 99.0 21.4 38.8 33.9 Yes NO Video TapeAmbient Temp.: 74°F Wind Speed/Dir.: 7 mph, 174°SComments: *Not required – indicant test, only.2720040769/7005

DATA SHEET 21EMERGENCY BRAKE STOPPING TESTPRIMARY CONTROL LINE FAILURE @ LLVWVehicle:__ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Initial/End Odo.:_1,407 / 1,432___Date:__05/24/07__ Driver:__R. Heberling Tech./Video:__R. LandesProject/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Requirements: Air system fully charged before each stop.Time:_11:15 – 12:30__IBTs: 150° to 200°F.With ABS - fully apply service brake; without - driver modulates control.Perform stops in neutral or with clutch depressed.One of the six stops MUST be equal or less than the requirement distance.Engage service brake any time after opening solenoid.StopDist. Req. (ft.) @ 60 mph: All Vehicles EXCEPT Tractors: 613; Unloaded Tractors: 720.60 MPH EMERGENCY BRAKE STOPS - LLVW (Primary Control Line)Actual CorrectedWheel Lock-upApplication Initial Stopping Stopping In IndicationPressure Speed Distance Distance 12 foot Position, Spd.(psi) (mph) (feet) per SAE Lane? (mph), TimeJ299locked (sec.)1 90.1 59.3 217.8 222.8 Yes #3R – 30, 2.1; #3L –29, 2.0, both to end2 91.7 60.0 219.8 219.6 Yes #3L – 29, 2.0; #3R –28, 1.9 both to end3 89.3 59.9 233.4 234.5 Yes #3R – 29, 1.9; #3L -22, 1.4, both to end4 90.5 60.2 237.6 235.7 Yes #3L & R – 27, 1.8,both to endCommentsVideo TapeVideo TapeNoneNone5 90.3 59.7 240.5 242.8 Yes #3R – 30, 2.0; #3L – None20, 1.3 both to end6* 87.6 20.8 36.0 33.3 Yes NO Video TapeAmbient Temp.: 80°F Wind Speed/Dir.: 6 mph, 205° SWComments: *Not required – indicant test, only.2820040769/7005

ROAD TESTSDATA SHEET 22PARK BRAKE TEST20% GRADE HOLDING - LLVWVehicle:__ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701____ Initial/End Odo.:_1,435_/ 1,435___Date:__05/24/07__ Driver:__R. Heberling Tech./Video:_R. Landes/S. WagonerProject/Segment Nos.:___20040769/7005___Ambient Temperature: 32° to 100°F.Parking Brake Chamber(s) Pressure 0 psiTime:_13:35 – 13:55___IBT’s: 150° to 200°F.20% GRADE HOLDING - LLVWGVWRX LLVWInitial BrakeTemperature(s)(ºF)Hottest BrakeControlPressure toHold Vehicle(psi)Movement toBecomeStationary onGrade(inches)Stationary on GradeFor 5 minutesYesNoUp Grade* 171 18 0 XDown Grade 163 18 0 XAmbient Temp.:Wind Speed:Direction:82° F7 mph169° SREMARKS: The test vehicle remained stationary on the grade facing both upgrade anddowngrade for the required five-minute period. Both directions were video taped.2920040769/7005

DATA SHEET 23FINAL INSPECTIONVehicle:__ 2007 TEBCO TG (6X4) Dump TruckTRC Vehicle No.:__C70701_____ Final Odo.:_1,455___Project/Segment Nos.:___20040769/7005___Date:__06/04/07_ Driver:_NA______ Tech.: R. Landes_Time:___10:30____Brake Stroke Measurements @ 85 PSI (in.)“Free-Stroke” Measurements (in.)Axle 1 Left/Right 1 3/8 / 1 Axle 1 Left/Right 1/2 / _1/2_Axle 2 Left/Right 2 / 2 Axle 2 Left/Right 3/4 / _3/4_Axle 3 Left/Right 2 / _ 2 _ Axle 3 Left/Right 3/4 / _9/16Axle 4 Left/Right N/A / _ N/A _ Axle 4 Left/Right N/A / _N/A_SERVICE BRAKESAll Brakes Structurally Intact: X Yes NoAll Brakes Function Properly: X Yes NoAll Brakes Adjusted Within Manufacturers Recommendation: X YesOverall Condition of Test Vehicle: Good - Used.NoTires replaced: ___Yes _X__NoNew Brake Linings: Axle #1 _X _Yes __No; Axle #2_X_Yes __No;Axle #3_ _Yes _ No; Axle #4_ _Yes __NoAdditional Comments:Overall condition of the foundation brakes, post-test, would be described as normal inappearance and color and contact area. No fractures or separations were present.Some glazing was present on all linings. Additionally, the drum’s appearance would bedescribed as normal, smooth, high polish with light to moderate material transfer anddebris.3020040769/7005

Section 5.0Instrumentation List3120040769/7005

Instrumentation ListInstrumentationA-DAT DSR-6 RadarFifth WheelLock-Up DetectionSystemTreadle PressureTransducerPressure TransducerPressure TransducerPressure TransducerPressure TransducerSerial Number(I.D. No.)Calibration DateNextCalibrationDate140.00182 Daily on a measured mile N/ATRC Prop. Calibrated before test N/APT-897090PT-359018PT-351132PT-169755PT-355434Calibrated before test usinga dead weightCalibrated before test usinga dead weightCalibrated before test usinga dead weightCalibrated before test usinga dead weightCalibrated before test usinga dead weightN/AN/AN/AN/AN/AMansfield-Green DeadWeight CalibratorSetra Accelerometer A-167627DW-6253 04/20/07 04/20/08Calibrated before testutilizing known calibratedinclines.Davis Weather Sys.6152A50609A02 06/11/06 06/11/07Thermocouples T52-0B-24K Calibrated before test N/AToledo Mettler ScalesJXGA-5318823-5KD02/26/07 05/26/07WIKA, Tire PressureGauge (0-160 psi)N/AAG-101 05/02/07 08/02/07LINK System 2060 2101 09/28/06 09/28/07Toshiba PC (used withLINK)43248 N/A N/A3220040769/7005

APPENDIX APHOTOGRAPHS

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Front View @ GVWR

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Side View @ GVWR

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Side View @ GVWR

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Rear View @ GVWR

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Front View @ LLVW

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Side View @ LLVW

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Side View @ LLVW

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Rear View @ LLVW

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Final Stage Manufacturer’s Placard

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Incomplete Vehicle Manufacturer’s Placard

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Body Manufacturer’s Placard

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Wet/Supply and Secondary (Top) and Primary (Bottom) Reservoirs

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Front/Steer Brake Assembly

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Front/Steer Brake Chamber

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Front/Steer Brake Slack Adjuster

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Front/Steer Brake Thermocouple Installation

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Left Front/Steer Brake ABS Wheel Speed Sensor

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Intermediate Drive Axle Brake Assembly

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Intermediate Drive Axle Brake Chamber

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Intermediate Drive Axle Brake Slack Adjuster

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Intermediate Drive Axle Brake Thermocouple Installation

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Rear Drive Axle Brake Assembly

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Rear Drive Axle Brake Chamber

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Rear Drive Axle Brake Slack Adjuster

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Rear Drive Axle Brake Thermocouple Installation

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Tandem Drive Axle Brakes ABS Modulator

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Right Rear Drive Axle Brake Wheel ABS Speed Sensor

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Rear Brakes R12 Valve

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Rear Brakes Parking Brake Valve

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Air Dryer

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Instrumentation in Vehicle

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Ballast in Vehicle

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Ballast in Vehicle

2007 TEBCO TG(6x4) Dump TruckNHTSA No. C70701May 2007Dash Warning Lamps

APPENDIX BTEST DATA FROM REPORT GENERATOR

APPENDIX CENGINEER’S TEST COMMENTS

Though the vehicle was ABS equipped, during the Primary Control Line Failure stops, at LLVW, therear drive axle was locking – both sides. The lockup would not occur initially, rather during the midportionof the effect stop and continue on to the end.For Data Sheet 17, “Apply Time” is the time from the first movement of the service brake controluntil the service brake control line pressure reaches 85 psi. (Note: Accelerometer affixed to theservice brake control to detect first movement.)Per OVSC and as an indicant test, a 20 mph stop was performed at the end of each stop sequence.