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TLIB307C - Carry Out Vehicle Servicing and Maintenance - Learner Guide
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TLIB307C
Carry out vehicle
servicing and
maintenance
Learner Guide
Contents
What this Learner’s Guide is about ........................................ 1
Planning your learning ........................................................... 2
How you will be assessed ...................................................... 5
Section 1............................................................................................. 7
Diagnose basic faults and undertake repair for the safe
operation of a vehicle ............................................................. 7
Section 2........................................................................................... 39
Carry out minor repairs to a vehicle ..................................... 39
Section 3........................................................................................... 55
Tyre maintenance and repair ............................................... 55
Additional resources ....................................................................... 76
Feedback on activities .................................................................... 78
TLIB307C Carry out vehicle servicing and maintenance
What this Learner’s Guide is about
This
Learner’s
Guide
is
about
the
skills
and
knowledge
required
to
carry
out
basic
servicing
and
maintenance
of
a
commercial
vehicle,
including
action
to
implement
the
vehicle
manufacturer's
specifications
for
routine
checks
and
maintenance
and
to
ensure
that
all
specified
safety
requirements
are
met
and
that
the
vehicle
is
operational
to
the
requirements
of
both
the
workplace
and
the
relevant
state/territory
roads
and
traffic
authority.
The
Elements
of
Competency
from
the
unit
TLIB307C
Carry
out
vehicle
servicing
and
maintenance
covered
in
this
Learner’s
Guide
are
listed
below.
Maintain
and
service
the
vehicle
systems
Carry
out
minor
repairs
to
a
vehicle
Diagnose
minor
vehicle
faults
and
undertake
repairs
for
the
safe
operation
of
a
vehicle
Complete
documentation
This
unit
of
competency
is
from
the
Transport
and
Logistics
Training
Package
(TLI07).
© Australian National Training Authority 2003 Page 1
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Planning your learning
It
is
important
to
plan
your
learning
before
you
start
because
you
may
already
have
some
of
the
knowledge
and
skills
that
are
covered
in
this
Learner’s
Guide.
This
might
be
because:
• you
have
been
working
in
the
industry
for
some
time,
and/or
• you
have
already
completed
training
in
this
area.
Together
with
your
supervisor
or
trainer
use
the
checklists
on
the
following
pages
to
help
you
plan
your
study
program.
Your
answers
to
the
questions
in
the
checklist
will
help
you
work
out
which
sections
of
this
Learner’s
Guide
you
need
to
complete.
This
Learner’s
Guide
is
written
with
the
idea
that
learning
is
made
more
relevant
when
you,
the
learner,
are
actually
working
in
the
industry.
This
means
that
you
will
have
people
within
the
enterprise
who
can
show
you
things,
discuss
how
things
are
done
and
answer
any
questions
you
have.
Also
you
can
practise
what
you
learn
and
see
how
what
you
learn
is
applied
in
the
enterprise.
If
you
are
working
through
this
Learner’s
Guide
and
have
not
yet
found
a
job
in
the
industry,
you
will
need
to
talk
to
your
trainer
about
doing
work
experience
or
working
and
learning
in
some
sort
of
simulated
workplace.
Page 2 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Section 1: Identify various components of a
commercial vehicle and describe
their operation
Are you able to: Yes No
1. identify nominated components of a
commercial vehicle?
2. describe the operation of the electrical
system, trace the system and identify the
major components?
3. carry out basic fault diagnosis and repair to
a commercial vehicle electrical system?
4. describe the operation of the fuel system,
trace the system and identify the major
components?
5. carry out basic fault diagnosis and repair to
a commercial vehicle fuel system?
Section 2: Describe safe use maintenance of
hand tools and undertake minor
repairs
Are you able to: Yes No
1. describe safe commercial vehicle
workshop activities?
2. demonstrate the correct use and
maintenance of basic hand tools?
3. undertake minor repairs to a commercial
vehicle?
© Australian National Training Authority 2003 Page 3
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Section 3: Tyre changing and principles of
wheel technology
Are you able to: Yes No
1. describe the safety procedures associated
with mounting and dismounting truck
tyres?
2. describe the principles of tyre and wheel
technology, identify and explain the
cause(s) of tyre wear patterns?
3. dismount and remount a commercial
vehicle wheel?
4. disassemble and reassemble a multipiece
commercial vehicle wheel trim?
5. repair a puncture in a commercial vehicle
tyre inner tube?
Page 4 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
How you will be assessed
Assessment
of
this
Unit
of
Competency
will
include
observation
of
real
or
simulated
work
processes
using
workplace
procedures
and
questioning
on
underpinning
knowledge
and
skills.
It
must
be
demonstrated
in
an
actual
or
simulated
work
situation
under
supervision.
You will be required to:
• change a fuse in a vehicle
• replace a tail light (or other) lens
• change a wheel.
© Australian National Training Authority 2003 Page 5
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Page 6 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Section 1
Diagnose basic faults and
undertake repair for the safe
operation of a vehicle
© Australian National Training Authority 2003 Page 7
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Section outline
Areas covered in this section
Identify nominated components of a commercial vehicle
Describe
the
operation
of
the
electrical
system,
trace
the
system
and
identify
the
major
components
Carry
out
basic
fault
diagnosis
and
repair
to
a
commercial
vehicle
electrical
system
Describe
the
operation
of
the
fuel
system,
trace
the
system
and
identify
the
major
components
Carry
out
a
basic
fault
diagnosis
and
repair
to
a
commercial
vehicle
fuel
system
Page 8 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Describe the operation of the electrical system
The
various
electrical
systems
fitted
in
a
motor
vehicle
are
designed
to:
• allow
the
vehicle
to
be
operated
safely
regardless
of
the
road
or
weather
conditions
and
the
time
of
the
day
• alert
the
driver
when
a
problem
occurs
with
any
of
the
vital
systems
• provide
adequate
comfort
for
the
driver
and
passengers
• indicate
to
the
driver
that
the
electrical
parts
are
operating.
A basic electrical system has:
• a power supply, to provide electrical energy
• a protective device, to protect the system from serious
damage
• a control unit, to connect and disconnect the power to or
from the work unit
• a work unit, to produce heat, light, movement or sound
• leads and cables, to attach each of the parts to the circuit.
To suit the motor vehicle application the circuit is usually:
• single pole, insulated copper wires carry the current from
the positive terminal of the power supply to the work unit
• negative earth return where the chassis or the body
returns the current from the work unit to the negative
terminal of the power supply.
Note that some vehicles have positive earth return.
© Australian National Training Authority 2003 Page 9
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Safety and warning devices
When
a
vehicle
is
being
used
between
dusk
and
dawn,
regardless
of
weather
conditions,
it
is
important
that
the
road
and
its
surroundings
are
clearly
illuminated
and
other
road
users
are
alert
to
your
intentions.
The
system
that
achieves
these
functions
will
include:
1. Headlights,
to
illuminate
the
road
ahead
for
a
distance
that
will
give
you
sufficient
time
to
react
to
any
change
in
conditions.
A
switch
allows
the
light
beam
to
be
dipped
which
will
prevent
the
drivers
of
oncoming
traffic
from
being
dazzled.
Two
or
four
lights
are
mounted
on
the
front
of
the
vehicle
and
are
controlled
by
switches
which
you
can
easily
reach.
2. Park,
tail
and
number
plate
lights
to
convey:
− the
vehicle’s
size
and
its
position
on
the
road
at
night
− to
illuminate
the
rear
number
plate.
3. Indicator
lights,
to
provide
a
flashing
signal
to
indicate
the
direction
the
vehicle
is
going
to
turn.
The
operating
switch
is
located
on
the
steering
column.
4. Clearance
lights,
located
on
the
sides
and
across
the
front
and
rear
of
the
vehicle
to
indicate
to
other
road
users
the
size
of
your
vehicle.
5. Horn,
to
provide
a
signal
that
will
attract
the
attention
of
other
road
users.
The
horn
button
is
located
on
the
steering
wheel
or
the
steering
column.
6. Windscreen
wipers
and
washers,
to
provide
a
clear
vision
through
the
windscreen
under
all
weather
conditions.
In
some
cases,
a
similar
device
is
used
to
clean
the
rear
window
and
the
headlights.
Its
control
switch
is
on
the
instrument
panel
or
on
the
steering
column.
7. Heater
and
demister,
to
remove
condensation
from
the
inside
of
the
windscreen
and
windows.
The
two
systems
used
are:
− a
warm
air
stream
passed
over
the
inner
surface
of
the
windscreen
the
heater/demister
unit
using
the
heat
from
the
engine’s
cooling
system
to
warm
the
air
− a
heating
element
placed
in
the
rear
window
glass
using
the
heat
from
the
element
to
warm
the
glass.
These
are
controlled
by
a
set
of
switches
and
levers
located
on
the
instrument
panel.
Page 10 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
8. Stop
lights
consisting
of
two
red
lights
to
warn
other
road
users
at
the
rear
of
the
vehicle
that
the
brakes
have
been
applied
and
the
vehicle
is
slowing
down.
These
lights
are
bright
enough
to
be
seen
in
sunlight
and
located
at
the
rear
of
the
vehicle.
Their
switch
is
located
in
the
braking
system
and
is
operated
by
the
movement
of
the
brake-‐
pedal
or
by
hydraulic
pressure
as
the
brake
is
applied.
They
may
be:
− combined
with
the
tail-‐lights
− positioned
in
the
mudguards,
rear
window
or
included
in
the
rear
light
assembly.
© Australian National Training Authority 2003 Page 11
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 1: What is the purpose of lights on a vehicle
What is the purpose of headlights on a vehicle?
____________________________________________________
Why does a vehicle have reversing lights?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
What do the instrument lights in a motor vehicle do?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
There is feedback on this activity at the back of this Learner’s
Guide.
Page 12 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 2: Draw your vehicle dashboard and illustrate various
controls
In the blank space provided below draw your vehicle’s dash and
the instrument panel. Locate on your drawing the various
instrument controls.
© Australian National Training Authority 2003 Page 13
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Instruments and gauges
For
the
safe
operation
of
the
vehicle
and
the
engine,
it
is
necessary
for
you
to
be
able
to
monitor
the:
• condition
of
the
vital
fluids
(oils,
fuel
and
water)
• output
of
the
charging
system
• operation
of
other
electrical
warning
systems
• vehicle
road
speed.
Each
of
these
is
monitored
by
a
gauge
or
a
light
switch
which
is
controlled
by
a
sender
unit.
The most common circuits are to:
• engine oil pressure indicator indicate to low oil-‐pressure
• engine coolant temperature indicator warn of overheating
• charging indicator to indicate the charging system’s
condition
• fuel gauge to display the amount of fuel in the fuel tank
• speedometer (may be a mechanical, electrical or electronic
device) to register the number of kilometres per hour the
vehicle is travelling and the number of kilometres the
vehicle has travelled
• brake failure warning light to warn of brake failure
• turn signal indicators to show which set of indicators are
being used and that they are operating correctly
• high beam warning light to alert the driver that headlights
are on high beam
• park brake ‘ON’ indicator to warn that the park brake is on
• rear window demister ‘ON’ indicator to show that the rear
window demister is on
• tachometer or clock when fitted to register the engine’s
rpm or displays the time, respectively.
These
lights
and
gauges
are
grouped
together
on
the
instrument
panel.
The
instrument
panel
is
designed
so
that
it
can
be
viewed
easily
by
the
driver.
Page 14 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Ancillaries (accessories)
Ancillaries
are
electrical
circuits
installed
to
add
to
the
comfort
and/or
pleasure
of
those
persons
travelling
in
the
vehicle.
Some
of
these
circuits
provide
the
following
features:
• cigarette
lighter
• clock
• radio
and/or
cassette
player
• trailer
socket
• extra
lights.
Testing equipment
The
common
types
of
testing
equipment
used
to
detect
faults
in
the
body
electrical
system
are
the:
• ammeter
• voltmeter
• ohmmeter
• test-‐light
• series
test-‐light.
The
voltmeter
and
the
ohmmeter
may
be
combined
in
one
meter
called
a
multimeter.
The ammeter
The
ammeter
is
used
to
measure
the
current
flow
in
a
circuit.
It
must
be
physically
connected
in
a
series
with
the
circuit
under
test.
The voltmeter
The
voltmeter
is
used
to
measure
the
electrical
pressure
applied
to
a
circuit
or
the
difference
in
electrical
pressure
(voltage
drop)
across
a
component.
The
highest
scale
should
be
selected
before
the
first
reading
is
observed.
The
scale
which
gives
the
most
accurate
reading
can
then
be
selected.
© Australian National Training Authority 2003 Page 15
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
The ohmmeter
The
ohmmeter
is
used
to
measure
the
resistance
in
a
circuit
or
a
component.
It
is
connected
across
the
circuit
or
the
component’s
input
and
output
terminals
with
the
battery
disconnected.
In
some
cases,
it
is
necessary
to
disconnect
the
component
from
the
circuit
so
that
an
accurate
reading
can
be
obtained.
To
prepare
an
ohmmeter
for
measuring
the
resistance
of
a
component,
you
must;
• connect
the
red
and
black
test-‐leads
to
the
red
and
black
ohmmeter
terminals
• select
the
lowest
scale
• zero
the
needle:
− turn
the
adjusting
knob
in
the
direction
required
to
set
the
needle
above
the
zero
mark
• disconnect
the
two
test-‐probes.
The test-‐light
The
test
light
is
used
to
visually
check
that
voltage
is
being
applied
to
a
component.
It
is
connected
between
any
circuit
lead
or
terminal
and
body
(earth)
while
the
circuit
is
switched
on.
The
brilliance
of
the
light
indicates
roughly
the
voltage
being
applied.
The series test-‐light
The
series
test-‐light
is
used
to
check
the
continuity
of
a
low
resistance
component
such
as
a
switch
or
a
low
tension
(LT)
lead.
It
can
be
used
to
check
for
a
short
circuit.
It
is
connected
across
the
component’s
input
and
output
terminals
with
the
circuit
switched
off
or
the
battery
disconnected.
In
some
cases,
it
may
be
necessary
to
disconnect
the
LT
leads
from
the
components
to
obtain
the
correct
reading.
Test methods
The
following
tests
can
be
carried
out
on
body
electrical
components
and
the
vehicle
circuits:
• resistance
• voltage
drop
• continuity
• current
flow
• short
circuit
• open
circuit
• internal
short
circuit.
Page 16 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Fault diagnosis
Test a component for a short circuit using a series test-‐light by
following the steps below:
1. prepare the series test-‐light
2. disconnect the input and output from the component
− use a suitable tool to disconnect the screw type
− pull on the terminal cover to disconnect the push-‐on type
3. connect the red test clip to the input terminal and the
black test clip to the body (earth) on the component
4. turn on the test-‐light switch
5. observe the test-‐light
− the light will glow when a short circuit exists
6. turn off the test-‐light switch
7. disconnect the test-‐light clips from the component
8. connect the LT leads to the component and make sure
they are secure
9. check the operation of the circuit.
© Australian National Training Authority 2003 Page 17
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 3: Demonstrate the use of electrical test equipment
Demonstrate for your trainer or your mechanic the use of each
electrical test equipment with the following exercises:
• measure the current flow through an electrical part
• measure the voltage drop across an electrical part or circuit
• test a part for a short circuit with a series of test lights
• measure the resistance of a part.
Ask your trainer or the mechanic to interpret the circuit test results
Do you use other items of safety equipment that have not been
listed in this Learner’s Guide?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Page 18 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Removing, rewiring and replacing electrical
parts
Any
attempt
to
drive
your
vehicle
when
a
body
electrical
part
has
been
removed
from
its
circuit
may
be
dangerous
and
must
be
prevented
by
correctly
preparing
your
vehicle.
To
prepare
your
vehicle
for
the
removal
and
replacement
of
body
electrical
parts:
• park
your
vehicle
on
a
flat
level
surface
• select
neutral
and
chock
the
wheels
• apply
the
park
brake
• disconnect
the
battery.
© Australian National Training Authority 2003 Page 19
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 4: Remove and replace your battery
Remove and replace your battery. Ask your trainer to check your
work.
Did the learner Yes No
• ensure that all vehicle electrical switches
were switched off?
• remove the earth lead:
− loosen the terminal nut and spread the
clamp with a screwdriver
− if it was a very tight terminal did the
learner removed it with a puller or
remover
− remove the spring terminal with a pair of
pliers or pincers?
• loosen and remove the live terminal?
• unscrew the nuts or screws holding the
battery securing clamp?
• remove the battery clamp?
• lift the battery out of the vehicle?
• use a battery sling to remove the battery
when if it was in an awkward position?
• clean the battery posts and terminals?
• carefully lift the battery into its cradle:
− use a battery sling to replace battery?
• replace and tighten the live lead:
− position the lead and lower the terminal
on to its post
− ensure no damage was caused to the
seal between the case and the post (e.g.
by hammering it into place)
− firmly tighten the clamping bolt?
• replace and tighten the earth lead?
Page 20 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Did the learner Yes No
• smear the terminals and posts with
petroleum jelly to prevent corrosion:
− thoroughly clean tools in boiling water to
remove battery acid that would etch
them quickly?
• demonstrate the correct use of the following
hand tools:
− pliers
− screwdrivers
− spanners including socket, box or open
ended?
• demonstrate the cleaning and storage of all
tools used?
• document the removal and replacement of
battery in accordance with company
procedure?
Test a part for a short circuit with a series test-light
Did the learner Yes No
• prepare the series test-light, connect input
lead to the vehicle’s battery?
• disconnect the input and output leads from
the part:
− use a suitable tool to disconnect the
screw type
− pull on the terminal cover to disconnect
the push-on type?
• connect the red test-clip to the input terminal
and the black test-clip to the body (earth) on
the part being tested?
• turn on the test-light switch?
• observe the test-light to see if light glowed
the light will glow when a short circuit exists?
• turn off the test-light switch?
© Australian National Training Authority 2003 Page 21
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TLIB307C Carry out vehicle servicing and maintenance
Did the learner Yes No
• disconnect the test-light clips from the part?
• disconnect the test-light input lead from the
vehicle’s battery?
• reconnect the input and output leads to the
part make sure they are secure?
• check the operation of the circuit?
Remove and replace a corroded LT terminal on a vehicle
component. Ask your trainer for feedback on your performance.
Page 22 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 5: Remove and replace a headlight unit
Demonstrate for your trainer or mechanic the removal and
replacement of a headlight (not affecting aim) on your vehicle. Ask
your trainer or your mechanic for assistance if required.
© Australian National Training Authority 2003 Page 23
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TLIB307C Carry out vehicle servicing and maintenance
Short circuit in your vehicle
The
shorting
out
or
continuous
globe/fuse
failure
could
be
caused
by
a
wire
that
has
been
damaged
and
is
shorting
out
on
the
vehicle
body.
This
problem
can
also
be
caused
by
having
an
incorrect
size
fuse
(
too
small
for
the
given
current
flow).
To
repair,
check
fuse
and
replace
with
the
correct
type
with
the
specific
amp
rating
to
make
sure
of
the
maximum
protection
to
the
circuit.
Page 24 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 6: Remove and replace an electrical fuse in your
vehicle
Replace an electrical fuse in your vehicle. Ask your trainer to check
your work.
Did the learner Yes No
• correctly locate fuse box?
• check fuse size (use the manufacture’s
manual to check size of fuse)?
• obtain correct size of fuse from the store?
• install fuse correctly?
• check the circuit for operation of the fuse?
• demonstrate the correct use of the following
hand tools:
− pliers
− screwdrivers
− spanners including, socket box or open
ended?
• demonstrate the cleaning and storage of all
tools used?
Replace a faulty electrical low tension lead. Ask your trainer to
check your work.
Did the learner Yes No
• select a roll of new LT lead with the same
amp rating or a higher amp rating than the
original?
• select the same colour wire for identification
purposes
• select suitable terminals and terminal covers
• use the same type as those which were cut
from the old lead?
• measure the length of the original lead and
cut the same length from the roll?
© Australian National Training Authority 2003 Page 25
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TLIB307C Carry out vehicle servicing and maintenance
Did the learner Yes No
• correctly fit the terminal covers to the lead?
• lay the lead along the wiring harness?
• release the wiring harness tabs or spring
clips?
• use insulation tape (or clips) to secure the
lead to the wiring harness in several places?
• reclamp the wiring harness to the body?
• connect both ends of the lead to their
respective parts?
• connect the battery and check the operation
of the circuit?
Page 26 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 7: What could be the reason your headlights are not
working?
Think about why your headlights might not work. List below six
reasons why your headlights may not work.
1 ___________________________________________________
2 ___________________________________________________
3 ___________________________________________________
4 ___________________________________________________
5 ___________________________________________________
6 ___________________________________________________
Ask your trainer if there are other reasons for your headlight failure.
Write down his/her answer.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
There is feedback on this activity at the back of this Learner’s
Guide.
© Australian National Training Authority 2003 Page 27
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TLIB307C Carry out vehicle servicing and maintenance
Replace tail-light lens
To remove lens from external light:
• determine the retaining method. It may be:
− two or more screws through the lens
− two or more screws through a retainer or a trim
• using a suitable screwdriver, remove the screws while
holding the lens
• remove the retainer (where applicable)
• grip the lens firmly and ease it away from the light body
• remove and discard the seal (if seal is damaged)
• obtain the replacement lens and seal from stores:
− make sure it is a genuine replacement part
• install a new seal (if necessary) to the body of the lens
• position the lens on the light body
• secure the retaining device:
− insert and tighten the retaining screws while the lens is held
firmly against the light body
• check that tail-‐lights are working.
Side mirrors
Side
or
door
mirrors
are
an
important
safety
item
on
your
vehicle.
They
allow
you
to
view
other
road
users
approaching
from
the
rear,
and
they
assist
in
the
reversing
of
your
vehicle
when
a
load
may
obscure
your
inside
mirror
viewing.
Page 28 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 8: Remove and replace a door mirror
Remove and replace a broken door mirror. Ask your trainer for
feedback on the completed task.
© Australian National Training Authority 2003 Page 29
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TLIB307C Carry out vehicle servicing and maintenance
Comparing petrol and diesel engines
Both petrol and diesel engines are internal combustion engines
working on either the two or four stroke cycle. The basic design of the
engines is similar. The main difference between the two is the method
of introducing the fuel charge into the combustion chamber, and the
means employed to ignite it.
Some advantages of using the diesel engine include:
• it uses less fuel than the petrol engine of a similar size.
• it is more economical.
• diesel fuel can be stored more safely than petrol (diesel
fuel is less volatile than petrol).
Fuel injection system
The
basic
fuel
injection
system
with
an
in-‐line
injection
pump,
consists
of
the
following
parts:
• fuel
tank
• fuel
tap
• fuel
lift
pump
• fuel
filter
• fuel
injection
pump
• governor
• fuel
injectors
• fuel
leak
off
pipe.
Page 30 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 9: Identify engine faults
Ask your trainer or your mechanic to analyse and assist you to
diagnose the following engine faults. Ask them why your engine
might:
• overheat?
• have low oil pressure?
• have power loss?
• stops after starting?
List their answers briefly.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
© Australian National Training Authority 2003 Page 31
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Fuel filters
There
are
five
common
types
of
filter
in
use,
they
are:
• resin
impregnated
paper
• felt
• cloth
• cotton
• ceramic
or
bronze.
Page 32 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 10: Remove and replace a fuel filter on your vehicle
Visually inspect the fuel filter on your vehicle for water and other
contaminants.
Remove and replace the fuel filter on your vehicle.
There is feedback on this activity at the back of this Learner’s
Guide.
© Australian National Training Authority 2003 Page 33
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TLIB307C Carry out vehicle servicing and maintenance
System operational sections
The
fuel
injection
system
can
be
divided
into
three
operational
sections,
consisting
of:
1. air
2. fuel
3. electrical.
The air system consists of:
• air snorkel, fresh air pick-‐up point for the air cleaner
• air cleaner, cleans the air entering the engine
• air flow meter or sensor.
The fuel section consists of:
• fuel tank and fuel reservoir providing a surge free pick-‐up
zone
• fuel pump, maintains fuel pressure within the system
• fuel pressure regulator, controls fuel pressure within the
system
• fuel filter, makes sure clean fuel is delivered to the
injectors
• fuel injector valve, fuel pressure mechanical or electrically
operated or activated.
The electrical system consists of:
• fuses and relays, devices that protect and switch the
circuit
• electronic control unit (computer), processes sensor
information and determines injection duration
• system sensor, provides computer with information in
relation to engine operational basis.
Page 34 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 11: Air cleaner servicing
Does your air cleaner filter require regular attention?
Yes No
If yes, why?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Remove and replace a dirty air cleaner filter. Ask your trainer for
feedback on your performance.
There is feedback on this activity at the back of this Learner’s
Guide.
© Australian National Training Authority 2003 Page 35
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Petrol cap
The
filler
cap
used
with
vapour
emission
control
systems
has
a
pressure-‐vacuum
valve
that
vents
air
into
the
tank
as
fuel
is
used
in
order
to
prevent
tank
collapse.
Fuel
vapour
cannot
vent
to
the
outside
atmosphere
unless
a
pressure
of
14
Kpa
(nominal)
above
atmosphere
is
reached.
Other petrol caps incorporate an anti-‐surge mechanism that prevents
fuel spillage through the cap due to surge when cornering.
Atmospheric air and fuel vapour are normally free to pass in and out of
the fuel system preventing tank collapse and/or excessive pressure
build up. In certain instances the anti-‐surge mechanism can prevent
fuel vapour from passing through the cap. However, pressure cannot
build in excess of 14 kPa (nominally) above atmospheric.
Repair broken fuel line
A
damaged
section
of
fuel
line
tubing
can
be
cut
out
of
the
existing
line
and
replaced
by
service
hose
and
two
retaining
clamps.
All
replacement
hoses
must
be
cut
to
a
length
that
will
make
sure
proper
clamp
retention
beyond
the
ends
of
the
connecting
tubing.
This
type
of
repair
should
be
considered
temporary
and
more
permanent
repairs
should
be
carried
out
as
soon
as
possible.
Installation of replacement fuel line
1. Use the same diameter tubing as the original
installation(s), and shape the new line(s). Avoid sharp
bends.
2. Cut the new line(s) to approximately the same length as
the original line(s). Allow an additional length for the
flaring operation.
3. Square off the ends with a file, and ream out the sharp
edges with the reamer blade on the tube cutter.
4. Position the new loom(s) (if used) on the new line(s).
Place new connections on the line, if required, and flare
the ends of the line(s) with the flaring tool. When
attaching a new line to fuel pump or any other fitting, be
sure to use a double lap flare in the line. Be sure metal
chips are removed from the inside of the tubing.
5. Install the connecting hoses and clamps, (if required) on
the fuel line(s). Position the line(s) in the clips on the
vehicle, and tighten the connection(s). Tighten the
connecting hose clamps, if so equipped.
6. Check the connections for leaks.
Page 36 © Australian National Training Authority 2003
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TLIB307C Carry out vehicle servicing and maintenance
7. Record work carried out in accordance with company
procedures.
Leaks in fuel tank
Proprietary
lines
are
available
that
will
allow
you
to
carry
out
a
temporary
repair
on
a
damaged
fuel
tank.
However,
it
is
important
that
the
fuel
tank
be
correctly
repaired
as
soon
as
possible.
It is not recommended that you attempt this repair yourself.
© Australian National Training Authority 2003 Page 37
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Page 38 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Section 2
Carry out minor repairs to a
vehicle
© Australian National Training Authority 2003 Page 39
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Section outline
Areas covered in this section
Describe safe commercial vehicle workshop activities
Demonstrate the correct use and maintenance of basic hand tools
Undertake minor repairs to a commercial vehicle
Page 40 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Tools and equipment
Tools
that
you
may
require
to
carry
out
testing
and
repairs
may
include:
• hammers
and
mallets
• pliers
(assorted)
• screwdrivers
(assorted)
• sockets
• spanners
• shifters
• grease
gun
• oil
filter
remover.
Equipment
that
you
may
require
to
carry
out
testing
and
repairs
may
include:
• timing
light
• tunescope
• wheel
aligner
• wheel
balancer
• battery
charger
• steam
cleaner
• air
compressor
• electric
drill
• bench
grinder
• bead
breaker.
Personal protective clothing and equipment may include:
• overalls
• gloves
• protective glasses
• ear protection
• hard hat.
© Australian National Training Authority 2003 Page 41
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 12: Check hand tools and equipment
Check your tools and equipment prior to use. Are they all in good
working condition? There has been room left for you to add other
tools or equipment.
Hand tool or Condition of tool or equipment. Yes
equipment Is the:
Open end • head in good condition − not
spanners stretched, cracked, broken or
damaged?
Tube spanners • hexagon in good condition − not
worn, rounded or corners split?
Socket spanners • drive socket in good condition:
− not worn or rounded?
− nut socket not rounded or split?
Screwdrivers • screwdriver in good condition:
− not worn, broken, bent or twisted?
− handles not split or broken?
Pliers • jaws and handles in good condition?
Hammers • strike face in good condition − handle
not split or broken, wedges in good
condition, head tight on the handle?
Pipe wrench and • jaw movement and adjusting nut in
adjustable good condition − not worn or
spanners damaged?
Oil filter tool • pivot pin, strut, spring steel band and
handle in good condition?
Page 42 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Hand tool or Condition of tool or equipment. Yes
equipment Is the:
Battery charge • mains power in good condition:
− gauges not broken or damaged?
− battery clips not sprung or
corroded?
Air compressor • power lead, air hose in good
condition:
− pressure gauge working?
− water drained from air chamber?
− oil at required level?
− compressor switches not broken
or damaged?
Bench grinder • power lead in good condition, safety
guards all fitted, on/off switches in
good condition?
© Australian National Training Authority 2003 Page 43
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 13: Adjust or replace your vehicle fan belt
Adjust or change a fan belt on your vehicle, and record this task for
future reference.
Check and adjust or replace fan belt
Prepared by:
Date:
Vehicle No:
Activity
completed
Check and adjust or replace fan belt Yes No
Check fanbelt for:
• glazing
• incorrect seating in pulley wheel
• cracks or other damage
• if belt is in good condition, adjust it.
Adjust loose fan belt:
• loosen pivot bolts
• loosen adjustment clamp bolt
• pull alternator towards you
• use of lever to tighten (if required)
• tighten clamp bolt
• tighten pivot bolts.
Replace fan belt:
• get correct belt size from existing belt
• check manufacturer’s manual for size
• follow steps for adjusting belt.
Remove and replace a faulty radiator hose.
Ask your trainer for feedback on the completed job.
Page 44 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Cooling system inspection
The
coolant
level
must
be
checked
regularly,
and
topped
up
as
required.
Cooling
systems
with
expansion
tanks
should
be
maintained
to
the
full
mark
on
the
expansion
tank.
On
other
systems,
you
are
required
to
remove
the
radiator
cap
to
check
the
coolant.
Check the cooling system:
1. Slowly turn the radiator cap anti-‐clock wise to
approximately 1/4 of a turn to release the steam pressure.
2. Press the cap down firmly, turn it a further 1/4 of a turn
anti-‐clock wise and lift cap off carefully.
3. Inspect the coolant for:
• correct level
• cleanliness
• rust
• discolouration of the coolant.
4. Top up coolant level if required.
© Australian National Training Authority 2003 Page 45
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 14: Check your cooling system for damage
Check cooling system for leaks and/or damage. Ask your trainer for
feedback on your performance.
Did the learner Yes No
• inspect the:
− radiator core
− tank joints
− drain plug?
• check the cylinder head gasket?
• check the radiator hoses for leaks and/or
damage:
− top
− bottom
− heater hose
− hose clamps?
• check the water pump seal?
• check the temperature gauge sender unit
for leaks or damage?
• check all welsh plugs for leaks?
• check engine drain plug?
• check the radiator core for obstructions
such as:
− dirt
− insects
− leaves
− oil
− bent or damaged fins?
Page 46 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Did the learner Yes No
• check hoses for:
− swelling
− hardness
− cracking
− perishing
− oil contamination?
• check the crankcase oil for water?
• check the fan for:
− looseness
− cracks
− bent blades?
• check fan belt for:
− tension
− cracks
− wear
− oil contamination?
© Australian National Training Authority 2003 Page 47
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Pressure testing the cooling system
At
times
it
becomes
necessary
to
pressure
test
your
radiator
to
check
for
the
elusive
leak
that
may
only
be
found
with
the
cooling
system
under
pressure.
Page 48 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 15: Pressure check your radiator
Pressure test your radiator components for leaks and/or damage,
replace hoses or cap if necessary.
Sub-task Did the learner Yes No
Test for external • remove the radiator cap
leaks
• top up the radiator coolant
level if required
• clamp the pressure tester to
the radiator filler neck
• pump the pressure tester
until the pressure was
approximately 25% above
that recommended for the
manufacture’s approved
cap
• inspect the radiator, hoses
and all connections for
leaks
• check the gauge reading to
see that it remained steady
(any drop in the system
gauge pressure would
indicate a leak in the
system)?
If no leaks were • check for an internal leak
detected and the from the water jacket or the
system continues to cylinder head
lose pressure, test
for internal leaks • remove the radiator cap
• top up the cooling fluid (did
they remember to leave an
air space)
• start the engine, run the
motor until it reached
operating temperature
• fit the pressure tester to the
radiator filler neck
© Australian National Training Authority 2003 Page 49
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Sub-task Did the learner Yes No
• pump the tester to
pressurise the system to
around 7-14 kPa
• check the pressure gauge
while the engine was
running (a sudden increase
in the pressure reading
indicates a fault in the
cylinder head or the head
gasket)?
Test the radiator cap. • check that the cap meets
the vehicle manufacture’s
recommendation for that
vehicle
• attach the radiator cap to
the pressure tester
• slowly pump the pressure
tester and check that
release pressure on the
gauge (the gauge will show
a definite drop and then
hold steady, as the valve
releases)
• find that the valve release
pressure was incorrect, or
the cap pressure did not
hold steady on the gauge
• replace the radiator cap
(after checking that the
replacement cap holds to
the required pressure)?
Page 50 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Remove and replace a top radiator hose on your vehicle.
Sub-task Did the learner Yes No
Replace top radiator • partially drain the radiator
hose system.
• loosen the clamps at
each end of the radiator
hose to be removed. slide
the hose off the
connections.
• position the clamps on
each end of the new
hose, slide the hose onto
the connections, then
tighten the clamps.
• position the clamps
beyond the beads on the
connections.
• fill the system with
coolant and bleed the
system.
• operate the engine for
several minutes, then
check the hose(s) and
connections for leaks?
Record the replacement of parts in accordance with your workplace
policy. Ask your trainer for feedback on your performance.
© Australian National Training Authority 2003 Page 51
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Care in the use of compressed air and air tools
Compressed
air
is
extensively
used
in
the
road
transport
industry
to
operate
pneumatic
tools,
such
as
wrenches,
drills,
grinders
and
sanders,
and
equipment
such
as
hoists,
tyre
bead
breakers,
air
jacks,
grease
guns,
etc.
It
is
also
used
for
parts
cleaning,
tyre
inflation
and
many
other
purposes.
Compressed
air
is
piped
around
most
work
areas.
You
must
learn
to
distinguish
the
air
supply
pipe
from
other
pipes.
Compressed
air
is
very
dangerous
when
used
for
anything
but
the
correct
purpose.
Pressures
of
690
kilopascals
(kPa)
or
more
are
quite
common.
Precautions when using compressed air
1. Before opening the valve from the air line, check that the
hose and connections are not damaged. Hold the end of
the hose to stop it whipping about when you turn the air
on.
2. Never use compressed air to clean your cloths or hair. Eye
damage or ruptured ear drums could result from this.
3. Never direct compressed air at another person. It can
cause serious injury or death.
4. Use rubber gloves if compressed air is used to clean spare
parts.
5. Wear goggles when drying parts and components with
compressed air.
6. Never blow down a bench or machine with compressed
air. It may blow metal filings dust or chips for 6 or 10
metres or more.
7. Do not used compressed air to blow brake lining dust from
shoes, drums etc.(asbestos dust is a health hazard). Use a
vacuum cleaner and brush.
8. Do not spin ball or roller bearings with compressed air as
they may fly apart causing injury. Damage to the bearing
will also result as the surfaces are not lubricated. The
bearing should be immersed in clean solvent and slowly
rotated by hand until clean.
Page 52 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 16: Identify the components of an exhaust system
Match the exhaust components to the corresponding letter.
A
B
C
D
E
F
A
B
There is feedback on this activity at the back of this Learner’s
Guide.
© Australian National Training Authority 2003 Page 53
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TLIB307C Carry out vehicle servicing and maintenance
Page 54 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Section 3
Tyre maintenance and repair
© Australian National Training Authority 2003 Page 55
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Section outline
Areas covered in this section
Describe the safety procedures associated with mounting and
dismounting truck tyres
Describe
the
principles
of
tyre
and
wheel
technology,
plus
identify
and
explain
the
cause(s)
of
tyre
wear
patterns
Disassemble and reassemble a multipiece commercial vehicle wheel
trim
Repair a puncture in a commercial vehicle inner tube
Page 56 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Tyres
Components
of
a
tyre
Although
tyres
are
finally
moulded
into
one
piece
they
are
built
up
from
these
components:
• the
casing
• the
beads
• the
tread
• the
side
walls
• the
inner
walls.
Rubber
compounds
are
used
in
the
construction
of
tyres.
These
compounds
have
the
following
advantages:
• ability
to
grip
the
road
surface
• good
shock-‐absorbing
qualities
• good
wear
resistance
• good
resistance
to
continual
flexing
• airtight.
Classification of tyres
Tyres are classified according to different characteristics:
• type of service:
− car
− motor cycle
− light truck
− truck
− tractor
• type of construction
− bias or radial ply
• tubed or tubeless
• type of tread
• ratio
− high or low
• load capacity
− ply or load rating.
© Australian National Training Authority 2003 Page 57
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TLIB307C Carry out vehicle servicing and maintenance
Activity 17: What type of tyres do you have on your vehicle?
Write what type of tyres you have on your vehicle.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Page 58 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Tyre construction
The
‘plies’
or
cord
material
used
in
the
casing
of
the
tyre
determine
the
shape
and
behaviour
of
the
tyre
when
it
is
inflated
and
running
on
the
road
under
load
and
traction
forces.
Depending
on
the
angle
the
plies
are
laid
across
the
tyre
during
manufacture,
the
tyres
may
be:
• bias
ply
(also
known
as
diagonal
or
cross
ply)
• belted
bias-‐ply
• radial-‐ply.
Different tyre constructions give different performance characteristics:
1. Bias-‐ply tyres are the oldest type still in use and are
suitable for all normal operating conditions. These have
two, four or more body plies which cris-‐cross at an angle of
approximately 35 degrees to the centre line of the tyre.
The plies are made of rayon, nylon, polyester or similar
material and the tyres are usually marked by size and ply
rating only.
2. Belted bias tyres have a similar body construction to the
bias or cross ply, plus two or more layers of fabric acting as
a belt between the tread and plies. They are identified by
the letter `B’ in the size marking.
3. Radial-‐ply tyres are more expensive to manufacture but
give longer tread life, better handling and the highest
capability. Because they have a lower rolling resistance,
they save on fuel consumption compared with bias-‐ply
tyre. Body cords or plies run from the bead to bead at 90
degrees to the centre line of the tyre. In addition, there are
two or more steel or fabric belts between the tread and
the plies. They are identified by the letter `R’ in the size
marking.
Tread patterns
Most
car
and
truck
tyres
have
‘all-‐purpose’
tread
designs
which
give
good
wear,
traction
and
quiet
running
under
most
road
surface
conditions.
Speed rating
The
tyre
chosen
must
have
a
speed
rating
equal
to,
or
greater
than,
the
maximum
speed
capacity
of
the
vehicle.
© Australian National Training Authority 2003 Page 59
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TLIB307C Carry out vehicle servicing and maintenance
The
rating
of
the
tyre
is
denoted
by
a
letter
included
in
the
tyre
identification
stamping.
The
letters
used
to
indicate
the
speed
rating
for
radial-‐ply
tyres
are:
1. ‘S’
180
km/h
2. ‘H’
210
km/h
3. ‘V’
over
210
km/h.
Selection of tyres
For
safe
operation,
the
tyres
fitted
to
a
vehicle
must
have:
• sufficient
load
carrying
capacity
• sufficient
speed
rating
• steering
stability
to
suit
the
vehicle
• clearance
from
the
body
and
chassis
• adequate
durability
(hardness).
When
replacement
tyres
are
fitted,
they
should
be
of
the
size
and
type
recommended
by
the
vehicle
manufacturer.
If
special
circumstance
require
different
tyres
to
be
fitted,
the
following
factors
must
be
considered:
• type
of
vehicle
• rim
size
• tyre
size
• tyre
load
capacity
• type
of
tyre
construction
• speed
rating
• tread
pattern
• regulations.
Tubes
Tubes
are
usually
made
from
synthetic
rubber
compounds,
such
as
‘butyl’
rubber,
which:
• is
impermeable
or
airtight
−
the
tyre
and
tube
holds
its
air
pressure
for
a
long
time
• can
be
repaired
−
patches
with
chemical
adhesives
are
used
which
do
not
require
heating.
Page 60 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 18: Describe your tyre rating
What is the speed rating of your truck tyres? (check your tyres)
____________________________________________________
____________________________________________________
____________________________________________________
What is the speed rating of your car tyres?
____________________________________________________
____________________________________________________
____________________________________________________
© Australian National Training Authority 2003 Page 61
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TLIB307C Carry out vehicle servicing and maintenance
Types of wheel
The
main
types
of
wheel
used
on
motor
vehicles
are:
• the
drop-‐centre
rim
wheel
−
used
on
most
passenger
cars
and
light
trucks
• the
flat-‐base
demountable
flange
rim
wheel
−
used
on
most
medium
and
large
trucks
• 15%
drop
centre
rim
wheels
−
used
on
medium
and
large
trucks
with
tubeless
tyres
• split
rim
(2-‐piece)
wheel
−
used
on
military
vehicles,
‘off-‐
the-‐road’
and
other
special
purpose
vehicles.
Change damaged wheel
For
your
own
safety
and
the
safety
of
others,
the
following
should
be
observed
when
changing
wheels:
• do
not
attempt
to
change
a
wheel
in
a
dangerous
situation
• locate
vehicle
in
a
safe,
level
and
firm
location
• apply
parking
brakes
and
chocks
to
wheel(s)
• place
warning
devices
in
position
on
road
• turn
on
hazard
lights
• loosen
wheel
nuts
before
you
jack
the
vehicle
• jack
up
vehicle
• use
safety
stand
• remove
wheel
• replace
wheel,
follow
correct
order
for
tightening
wheel
nuts
• remove
safety
stand
and
remove
jack
• fully
tighten
wheel
nuts
• stow
damaged
wheel
on
vehicle.
Recheck
rim
for
movement
and
wheel
nuts
for
tightness
after
50
km.
Repeat
after
a
further
50
km
if
a
problem
is
found.
Page 62 © Australian National Training Authority 2003
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TLIB307C Carry out vehicle servicing and maintenance
Removal and installation
The
tyre
must
be
completely
deflated
before
removal,
and
the
bead
must
not
be
damaged
by
a
tyre
iron.
After installation, a tube tyre should be inflated to recommended
pressure, deflated, and then reinflated again to make sure that the
tube is not folded inside the tyre. Make sure the tube flap is properly
positioned before inflating the tyre.
It is recommended that correct tyre-‐changing equipment be used in
changing all truck tyres.
Disassembly and assembly
Drop-‐centre tubeless rims and wheels
Demounting the tyre
1. Make certain the tyre is completely deflated with the valve
core removed.
2. With the tyre lying flat, loosen both beads by walking on
the tyre with the heels close to the rim.
3. With the wide side of the rim down, lubricate the top
bead.
4. With the stops toward the rim, insert the spoon ends of
the two tubeless tyre tools about 250 cm apart (Fig. 1,
View A). Holding the bead in the well with your foot, pull
one tool towards the center of the rim.
5. Hold the tool in position with one foot and pull the second
tool towards the center of the rim (Fig. 1, View B).
Progressively work the bead off the rim, taking additional
bites with the tools as necessary.
6. Stand the assembly in a vertical position. Lubricate the
second bead.
7. At the top of the assembly insert the straight end of the
tool between the bead and back flange of the rim at about
a 45 degree angle (Fig. 1, View C). Turn the tool so that it is
perpendicular to the rim. Pry the second bead off.
© Australian National Training Authority 2003 Page 63
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TLIB307C Carry out vehicle servicing and maintenance
8. Clean and inspect the wheel and tyre as previously
described.
Fig.
1.
Mounting the tyre
1. Be sure the right valve is used and properly installed in the
rim.
2. Inspect the rim to make sure the bead seats are clean and
smooth.
3. Place the rim on the floor with the wide side down and
lubricate the first bead of the tyre and upper bead seat of
the rim (Fig. 2, View A).
4. Push the first bead into the well of the rim and onto the
rim as far as possible. Using the straight end of the tool
(with stop resting on the rim flange) take small bites to
work the remaining section of the first bead onto rim (Fig.
2, View B).
5. Hold the second bead in the well by standing on the tyre
and anchor with the vice-‐grip pliers (snub side toward the
tyre).
6. Using the spoon end of the tyre tool with the stop towards
the rim, use small bites until the bead slips over the flange.
If necessary, insert the second tyre tool and lubricate last
150 cm of bead before completing the mounting (Fig. 2,
View C).
7. Inflate the tyre as previously described, making certain
that all the safety precautions are followed. Check for
leaks.
Page 64 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Fig. 2.
Semi-‐Drop Wheels
CAUTION: Demounting and mounting truck tyres can be extremely
dangerous if proper safety precautions are not followed.
Demounting the tyre
1. Place the tyre and wheel on the floor with the side ring up.
Make certain that the tyre is completely deflated and that
the valve core is removed.
2. To loosen the first bead, drive the hooked end of the rim
tool between the tyre and rim flange and press downward
on the bead (Fig. 3, View A).
3. Progress around the rim, using the two tools as shown in
View A.
4. To remove the ring, insert the tool in the notch and force
the ring opposite of the notch into the futter, then pry off
(Fig. 3, View B).
5. Pry out and up on the side ring, carefully but firmly. Take
care not to bend the side ring.
6. Force the upper tyre bead into the well opposite the valve
slot and with the tyre tool, pry the opposite portion of the
bead over the edge of the rim (Fig. 3, View C).
7. Turn the tyre over, and by means of rim tools, loosen the
bead on the opposite bead seat. Insert the straight end of
the tool between the bead and back flange of the rim at
about a 45 degree angle. Turn tool so that it is
perpendicular to the rim. Make sure one portion of the
second bead is still in the rim well, then pry the opposite
portion of the bead over the edge of the rim. This will free
the tyre (Fig. 1, View C).
Clean and inspect the wheel and tyre as previously described.
© Australian National Training Authority 2003 Page 65
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
A B C
Fig.3.
Page 66 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Mounting the tyre
1. Place the tyre on the rim so that the valve is in line with the
rim slot and insert the valve through the slot. Force the
first bead down into the well of the rim just to side of the
valve with foot. Mount the first bead over the rim lip with
the rim tool progressing from each side of the foot
approximately opposite foot (Fig. 4, View A).
2. To apply the second bead, start at the point opposite the
valve and press the tyre bead over the rim lip and into the
rim well with foot pressure. Mount the remainder of the
bead over the rim lip by means of thin tyre tool, being
careful not to pinch the tube. If necessary, insert the
second tyre tool and lubricate the last 150 cm of the bead
before completing the mounting (Fig. 4, View B).
3. Place the half of side ring opposite tool notch under the
rim lip with cutaway portions in the position as shown.
Force part of the ring directly opposite of the notch down
below the rim lip approximately 25 cm to aid in mounting.
Insert the thin end of the rim tool in the tool notch and pull
ring outward over the rim lip, while striking the ring with a
rubber mallet to start engagement over the rim. Remove
the rim tool, then strike the remaining portion of the side
ring to force it down over the rim lip (Fig. 4, View C).
4. Inflate the tyre as previously described in this Part, making
certain that all safety precautions are followed. Check for
leaks.
A
B
C
Fig. 4.
Two-‐Piece Rims and Wheels
CAUTION: Demounting and mounting truck tyres can be extremely
dangerous if proper safety precautions are not followed.
© Australian National Training Authority 2003 Page 67
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TLIB307C Carry out vehicle servicing and maintenance
Demounting the tyre
1. Place the tyre on the floor and make certain that the tyre is
completely deflated and that the valve core is removed.
2. Insert the hooked end of the tyre tools between the side-‐
ring and the side wall of the tyre and pry the bead loose
from the side-‐ring by downward pressure on the rim tools.
Continue prying progressively around the tyre until the
bead is completely free from the side ring (Fig. 5, View A).
3. Insert the tapered end of the tool into the prying notch on
the side ring and pry the side ring from the groove in the
rim by prying progressively around the tyre until the ring is
free (Fig. 5, View B).
4. Turn the assembly over and unseat the second tyre bead
from the rim. Lift the rim from the tyre (Fig. 5, View C).
5. Clean and inspect the wheel and tyre as previously
described.
A B C
Fig. 5.
Mounting the tyre
1. Insert
the
tube
flap
into
the
tyre
and
inflate
sufficiently
to
round
out
the
tube.
Apply
rubber
lubricant
to
the
inside
and
outside
surfaces
of
both
the
tyre
beads
and
to
that
portion
of
the
tube
and
flap
that
appears
between
the
beads.
2. Lay
the
rim
flat
on
the
floor
with
the
valve
slot
up.
Align
the
valve
with
the
valve
slot,
place
the
tyre
onto
the
rim
and
insert
the
valve
through
the
valve
slot
(Fig.
6,
View
A).
3. Place
the
side-‐ring
on
the
rim
base
so
that
the
ring
split
is
opposite
the
valve
stem.
Place
the
leading
end
of
the
ring
into
the
groove
(Fig.
6,
View
B).
Page 68 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
4. Starting
at
the
valve
side,
progressively
“walk”
the
side
ring
into
place
(Fig.
6,
View
C).
Check
to
see
that
the
ring
is
fully
seated
in
the
groove.
NOTE:
Openings
between
the
ends
of
the
split
side
ring
must
not
be
less
than
3
cm
except
where
the
ring
design
calls
for
an
abutting
condition,
or
more
than
3
cm
except
where
the
ring
design
calls
for
an
abutting
condition,
or
more
than
5
cm
inch
after
ring
is
seated
in
during
operation.
5. Inflate
the
tyre
as
previously
described,
making
certain
that
all
safety
precautions
are
followed.
Check
for
leaks.
A
B
C
Fig. 6.
Three-‐piece rims and wheels
CAUTION: Demounting and mounting tuck tyres can be extremely
dangerous if proper safety precautions are not followed.
Demounting the tyre
1. Place
the
tyre
and
wheel
on
the
floor
with
the
side
ring
up
and
make
certain
that
the
tyre
is
completely
deflated
with
the
valve
core
removed.
2. Insert
hooked
end
of
the
tyre
tools
between
the
side
ring
and
side-‐
wall
of
the
tyre
(Fig.
7,
View
A).
Pry
the
bead
loose
from
the
side
ring
by
downward
pressure
on
the
rim
tools.
Continue
prying
progressively
around
the
tyre
until
the
bead
is
completely
free
from
the
side
ring.
3. With
the
side
flange
and
tyre
bead
pushed
down,
insert
the
tapered
end
of
the
tool
into
the
notch
near
the
spot
in
the
lock
ring
and
push
downward
to
pry
the
lock
ring
from
the
gutter
groove
of
the
rim
base
(Fig.
7,
View
B).
4. Use
the
hooked
end
of
the
tool
to
complete
removal
of
the
lock
ring
progressively
working
around
the
tyre
(Fig.
7,
View
C).
Lift
off
the
side
flange.
© Australian National Training Authority 2003 Page 69
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TLIB307C Carry out vehicle servicing and maintenance
5. Turn
the
assembly
over
and
unseat
the
second
tyre
bead
from
the
rim.
Lift
the
rim
from
the
tyre.
Remove
the
tube
and
flap
(if
used)
from
the
tyre.
A B C
Fig. 7.
Mounting the tyre
1. Insert
the
tube
and
flap
(if
used)
into
the
tyre
and
inflate
sufficiently
to
round
out
the
tube.
Apply
rubber
lubricant
to
the
inside
and
outside
surfaces
of
both
the
tyre
beads
and
to
that
portion
of
the
tube
and
flap
that
appears
between
the
beads.
2. Lay
the
rim
flat
on
the
floor
with
the
valve
slot
up.
Align
the
valve
with
the
rim
valve
slot.
Place
the
tyre
into
the
rim
and
insert
the
valve
through
the
valve
slot
(Fig.
8,
View
A).
3. Place
side
flange
on
the
rim
base
and
stand
on
flange
to
position
the
flange
below
the
gutter
grooves
in
the
rim
base
(Fig.
8,
View
B).
4. Snap
the
leading
end
of
the
lock
ring
into
the
gutter
groove
of
the
rim
base
and
progressively
“walk”
the
lock
ring
into
place
(Fig.
8,
View
C).
Check
to
ensure
that
the
lock
ring
is
fully
seated
in
the
gutter
groove.
5. Inflate
the
tyre
as
previously
described,
making
certain
that
all
safety
precautions
are
followed.
Check
for
leaks.
A B C
Fig. 8.
Page 70 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 18: Repair puncture in a tube
Demonstrate for your trainer the repairing of a motor vehicle tube,
from a two piece rim and wheel. Repair the tube and test after
repair. Replace tube in tyre. Ask your trainer for feedback on your
performance.
Sub-task Steps did the learner Yes No
Demount the tyre • place the wheel on the
floor and fully release the
air pressure by removing
the valve core?
• insert the hooked end of
the tyre tools between the
side-ring and the side
wall of the tyre and pry
the bead loose from the
side-ring by downward
pressure on the rim
tools?
• continue prying
progressively around the
tyre until the bead is
completely free from the
side ring?
• remove the tube from the
tyre?
• turn the wheel over to
unseat the second tyre
bead from the rim and lift
the rim from the tyre?
• clean and inspect the
wheel and tyre for
damage?
© Australian National Training Authority 2003 Page 71
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TLIB307C Carry out vehicle servicing and maintenance
Sub-task Steps did the learner Yes No
Repair hole in the tube • inflate tube to locate
puncture?
• roughen area around
puncture?
• repair tube with
vulcanising patch or cold
repair patch?
• inflate and check tube for
other leaks?
• replace tube.
Mount the tyre on a • insert the tube and flap
divided-rim wheel. into the tyre and inflate
sufficiently to round out
the tube, then apply
rubber lubricant to the
inside and outside
surfaces of both the tyre
beads and to that portion
of the tube and flap that
appears between the
beads?
• lay the rim flat on the
floor with the valve slot
up. Align the valve with
the valve slot, place the
tyre onto the rim and
insert the valve through
the valve slot?
• place the side-ring on the
rim base so that the ring
split is opposite the valve
stem. Place the leading
end of the ring into the
groove?
Page 72 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Sub-task Steps did the learner Yes No
• starting at the valve side,
progressively `walk’ the
side ring into place, and
check to see that the ring
is fully seated in the
groove? Note: Openings
between the ends of the
split side ring must not be
less than 3 cm except
where the ring design
calls for an abutting
condition, or more than 5
cm after ring is seated in
during operation?
• inflate the tyre, making
certain that all safety
precautions are followed,
check for leaks?
• record work carried out in
accordance with
company procedures?
© Australian National Training Authority 2003 Page 73
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Tyre service
The
failure
of
a
tyre
or
a
wheel
can
easily
lead
to
the
loss
of
vehicle
control,
resulting
in
an
accident.
For
this
reason,
frequent
inspection
and
pressure
checks
are
necessary
for
safe
operation.
Careful
maintenance
of
inflation
pressures
and
repair
of
minor
damage
will
avoid
excessive
wear
and
the
early
replacement
of
expensive
tyre
equipment.
Most
tyre
failures
are
due
to
incorrect
inflation,
usually
under-‐inflation,
for
the
load
and
speed
at
which
the
tyre
is
operated.
The
excessive
flexing
of
the
tyre,
especially
the
sidewall,
when
under
inflated,
results
in
the
generation
of
higher
temperatures
in
the
tyre.
If
the
temperatures
are
high
enough,
the
bond
between
the
various
rubber,
textile
and
steel
components
of
the
tyre
can
be
broken
and
the
tyre
will
disintegrate.
Tyre failure due to other causes rarely results in immediate failure.
Detection
of
a
cause,
such
as
objects
embedded
in
the
tread,
or
faulty
wheel
alignment,
will
often
allow
correction
to
be
made
before
extensive
damage
requiring
tyre
replacement
takes
place.
Correct tyre service will include:
• checking and setting inflation pressures
• checking and adjusting wheel camber to manufacturer’s
specifications
• checking and adjusting wheel and tyre assembly for run-‐
out
• check wheel balance and correct by dynamic or static
balance
• inspection for minor damage and damage control.
How
often
the
tyres
of
a
vehicle
require
checking
for
inflation
pressure
and
damage
will
depend,
to
some
extent,
on
the
road
and
driving
conditions.
Ideally,
this
should
be
carried
out
at
least
as
often
as
the
vehicle
is
being
fuelled.
Experience
with
a
particular
type
of
vehicle
under
unchanging
operating
conditions
should
enable
an
effective
service
interval
to
be
established.
Page 74 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 19: Change a wheel on a motor vehicle
Change a wheel on a vehicle specified by your trainer, observing all
OHS requirements.
Ask your trainer to show you on motor vehicles in your workplace
examples of uneven tyre wear.
If there are no examples in your workplace, ask your trainer for
permission for you to go to your local tyre retailer, for printed
information on various tread wear patterns.
If this is not available, ask the tyre retailer to show you examples of
tread wear.
If you are able to obtain examples of tyre wear, stick these into your
learner’s guide.
Below are some examples of tyre wear and how it could have been
prevented.
Tyre wear patterns
© Australian National Training Authority 2003 Page 75
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Additional
resources
Page 76 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Paper
based:
• The
Australian
Truck
Drivers
Manual.
• Guidelines
for
the
safe
carriage
of
loads
on
road
vehicles,
Load
Restraint
Guide.
• State/Territory
regulation
authority
material,
e.g.
RTA
(NSW)
Heavy
Vehicle
drivers’
Handbook;
Vic
roads’
The
Victorian
Bus
and
Truck
Drivers’
Handbook.
Other
material
may
be
obtained
from
various
State/Territory
authorities.
• Relevant
government
Acts
and
legislation,
covering
heavy
vehicle
road
law
and
operation.
• Relevant
tyre
retailer
information
on
tyre
wear
and
the
reason
for
the
wear
(obtained
from
your
local
tyre
retailer).
• May
and
Crouse,
Motor
Mechanics,
Vol
1&2
4th
Ed.
• Schultz,
EJ.
Diesel
Equipment
1&2.
• Basic
training
Manual
17-‐1,
Workshop
Safety.
• Basic
Training
Manual
17-‐13,
Vehicle
Body
Electrical
Systems.
© Australian National Training Authority 2003 Page 77
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.
Page 78 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
TLIB307C Carry out vehicle servicing and maintenance
Activity 1: What is the purpose of lights on a vehicle
• illumination and to allow the vehicle to be driven at night
• illumination and to indicate to other road users that the vehicle
is being reversed
• light up the instrument panel and allows the driver to maintain a
watch on the instruments for problems.
Activity 7: What could be the reason your headlights are not
working?
Check why your headlights are not working? List below six reasons
why your headlights may not work.
• blown headlight fuse
• blown high and low-beam fuse
• loose or broken lead to headlight switch
• loose or broken lead to dipper switch
• faulty headlight switch
• faulty dipper switch.
Ask your trainer if there are other reasons for your headlight failure.
Write down his/her answer.
• faulty protection device
• blown filaments in both headlights.
Activity 11: Air cleaner servicing
Yes No
If yes, why?
The prime role of the air cleaner is to provide sufficient clean air to
the ignition system. If the cleaner is blocked or dirty it must be
removed and cleaned or replaced.
The air cleaner comes in two types, they are:
• oil bath air cleaner
• dry type air cleaner.
© Australian National Training Authority 2003 Page 79
Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064
TLIB307C Carry out vehicle servicing and maintenance
Activity 16: Identify the components of an exhaust system
Match the exhaust components to the corresponding letter.
A Pipe assembly
B Clamp assembly
C Extension muffler inlet pipe
D Muffler bracket support
E Muffler assembly
F Muffler pipe outlet
A Converter
B Muffler assembly
Page 80 © Australian National Training Authority 2003
ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009
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