TLIB307C - Carry Out Vehicle Servicing and Maintenance - Learner Guide

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

© Australian National Training Authority 2003 Page 1 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009 ADELG1064

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).


Page 2 © Australian National Training Authority 2003 ADELG1064 Customised and developed by Armstrong’s Driver Education Pty Ltd April 2009

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.



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


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?



Section 3: Tyre changing and principles of wheel technology


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?



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.



Section 1

Diagnose basic faults and undertake repair for the safe operation of a vehicle



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



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.



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.



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.



Activity 1: What is the purpose of lights on a vehicle

What is the purpose of headlights on a vehicle?

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Why does a vehicle have reversing lights?

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What do the instrument lights in a motor vehicle do?

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There is feedback on this activity at the back of this Learner’s Guide.



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.



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.



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.



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.



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.



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?

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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.



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?




• 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


• 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?




• 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.



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.



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.



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.


• 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.


• 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?




• 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?



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.

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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.



Activity 8: Remove and replace a door mirror

Remove and replace a broken door mirror. Ask your trainer for feedback on the completed task.



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.



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.

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Fuel filters

There are five common types of filter in use, they are:

• resin impregnated paper

• felt

• cloth

• cotton

• ceramic or bronze.



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.




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.



Activity 11: Air cleaner servicing

Does your air cleaner filter require regular attention?

Yes No

If yes, why?

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Remove and replace a dirty air cleaner filter. Ask your trainer for feedback on your performance.




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.



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.



Section 2

Carry out minor repairs to a vehicle



Section outline


Describe safe commercial vehicle workshop activities

Demonstrate the correct use and maintenance of basic hand tools

Undertake minor repairs to a commercial vehicle



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.



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 equipment

Condition of tool or equipment. Is the:

Yes

Open end spanners

• head in good condition − not 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 adjustable spanners

• jaw movement and adjusting nut in good condition − not worn or damaged?

Oil filter tool • pivot pin, strut, spring steel band and handle in good condition?



Hand tool or equipment

Condition of tool or equipment. Is the:

Yes

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?



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.



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.



Activity 14: Check your cooling system for damage

Check cooling system for leaks and/or damage. Ask your trainer for feedback on your performance.


• 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?




• 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?



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.



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 leaks

• remove the radiator cap

• 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 detected and the system continues to lose pressure, test for internal leaks

• check for an internal leak from the water jacket or the cylinder head

• 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




• 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)?



Remove and replace a top radiator hose on your vehicle.


Replace top radiator hose

• partially drain the radiator 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.



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.



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




Section 3

Tyre maintenance and repair



Section outline


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



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.



Activity 17: What type of tyres do you have on your vehicle?

Write what type of tyres you have on your vehicle.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



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.



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.



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?

____________________________________________________

____________________________________________________

____________________________________________________



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.



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.



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.



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.



A B C

Fig.3.



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.



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).



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.



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.



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?



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 divided-rim wheel.

• insert the tube and flap 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?



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?



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.



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



Additional resources



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.



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.



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.



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

TLIB307C - Carry Out Vehicle Servicing and Maintenance - Learner Guide

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Transcript of TLIB307C - Carry Out Vehicle Servicing and Maintenance - Learner Guide