TLIB407C - Carry Out Vehicle Inspection - Learner Guide

TLIB407C

Carry out vehicle

inspection Learner Guide

Contents

What this Learner’s Guide is about ........................................ 1 Planning your learning ........................................................... 2 How you will be assessed ...................................................... 5

Section 1............................................................................................. 7 Routine maintenance ............................................................. 7

Section 2........................................................................................... 31 Perform pre-operational vehicle inspection and checks....... 31

Section 3........................................................................................... 63 Undertake post-start up vehicle checks ............................... 63

Section 4........................................................................................... 91 Clean your vehicle and trailer............................................... 91

Additional resources..................................................................... 125

Feedback on activities .................................................................. 127

TLIB407C Carry out vehicle inspection

© Australian National Training Authority 2003 Page 1 Customised and Developed by Armstrong’s Driver Education P/L June 08 ADELG1032

What this Learner’s Guide is about

This Learner’s Guide is about the skills and knowledge required to carry out an inspection of a commercial vehicle, including action to implement the vehicle manufacturer's specifications for routine checks, to clean the vehicle 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 TLIB407C Carry out vehicle inspection covered in this Learner’s Guide are listed below.

Check the vehicle

Clean vehicle

Complete documentation

This unit of competency is from the Transport and Logistics Training Package (TLI07).


Page 2 © Australian National Training Authority 2003 ADELG1032 Customised and Developed by Armstrong’s Driver Education P/L June 2008

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: Routine maintenance

Are you able to: Yes No

1. use basic hand tools?

2. describe safe workshop activities?

3. use personal protective clothing?

4. handle lube oils and greases?

Section 2: Perform pre-operational vehicle inspection and checks


1. perform pre-‐operational vehicle inspections and checks?

2. test that all warning systems are operational and do not indicate any faults that may affect the operation of the vehicle?

3. check job accessories and test ancillary equipment?

4. follow testing procedures according to manufacturer’s specifications and company requirements?

5. demonstrate safe working procedures at all times?

Section 3: Undertake post-start up vehicle checks


1. start engine in accordance with manufacturer’s guidelines and start up procedures for operation?

2. monitor instruments and gauges to make sure of vehicle safety?

3. check various components of the vehicle to make sure they are operating according to



manufacturer’s specifications and safety rules?

4. record results from vehicle pre-‐operational and post-‐start up checks and report to your supervisor?

5. demonstrate safe working procedures at all times?

Section 4: Clean your vehicle and trailer


1. prepare equipment and materials for vehicle and trailer cleaning?

2. clean exterior of vehicle/trailer in accordance with manufacturer’s specifications and company requirements?

3. clean interior of vehicle in accordance with manufacturer’s specifications and company requirements?



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:

• replace a fuse

• replace a lens

• change a wheel.





Section 1

Routine maintenance



Section outline

Areas covered in this section

Safe workshop activities

Personal protective clothing

Basic hand tools

Handle lube oils and greases



Safe workshop activities

You must learn how to work without hurting yourself or endangering your fellow workers. Your own efforts are important in keeping your workplace safe.

Effects of industrial accidents

Accidents cause losses to everyone. If you have an accident you will suffer from:

• pain and inconvenience

• possible reduction of earnings

• being kept out of things, at work, in sport and in social activities.

Every year in Australia, hundreds of people are killed as a result of industrial accidents and thousands sustain some permanent injury. Many other injuries are not serious but the average time away from work is two weeks.

Cause of accidents

An accident often has more than one cause. Accidents can be prevented by removing their cause. Finding out what causes an accident is important. It can help in planning how to prevent similar accidents.

There are two causes of accidents:

1. Unsafe acts.

2. Unsafe conditions.

Think about these examples of unsafe acts:

• using tools or equipment without having proper training in their use

• using tools or equipment the wrong way

• failing to use personal protective equipment, such as goggles, gloves and helmets

• fooling around in dangerous situations

• hurrying and taking dangerous short cuts through the workplace



• distracting others from their work, or allowing yourself to be distracted.



Consider these examples of unsafe conditions for the worker:

• lack of instruction in safe methods

• lack of training

• unsuitable clothing for the task to be done

• long hair around rotating machines

• a lack of safety guards on machines.

Avoid unsafe acts

It is your responsibility to avoid unsafe acts. You must for your own sake and that of others, learn to work safely and efficiently. Any foolish act that could cause danger to yourself, or others, is an act of irresponsibility, even if you see other people taking risks.

Eliminate unsafe conditions

Safe working conditions are not only a matter of having good tools, machines and well designed workshops, they depend on the co-‐operation of everybody in the workplace.

Think about these examples of unsafe conditions in the workplace:

• slippery floors

• bad lighting

• an untidy or dirty workplace

• defective hand tools

• unguarded machinery

• poorly stacked materials.

Anything that can cause an accident is a hazard.

Prevent accidents

Accidents can be prevented by eliminating possible causes. The best people to work with are those who are alert and considerate, careful and responsible.



Try to:

• make your general behaviour safe

• prevent unsafe conditions developing

• segregate unsafe areas with barricades

• know what to do in an emergency.

Report all accidents, or damaged to equipment, no matter how minor they seem to be. Minor damage can develop into serious failures if not reported.



Activity 1: Demonstrate your knowledge on workplace safety

1. What kind of hazards are there in your workplace that may injure you or others if you do not follow safe working practices?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. How could you be affected by an accident in the workplace?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. Find out what accidents have happened in your workplace and explain how these accidents could have been prevented.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



4. Has anything been done to rectify the cause(s) of these accidents?

Yes No

If Yes, what was done to correct the problem?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

5. What is the most common accident that happens in your workplace?

Example: A lot of people cut their hands because

____________________________________________________

____________________________________________________

____________________________________________________

6. List unsafe conditions that you think may occur in your workplace.

Example: Cluttered walkways and passages.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Activity 2: Is your workplace a safe place to work in?

Tick the checklist:

1. Is your workplace a safe, clean and tidy place to work in?

Yes No • Does your workplace have good lighting? • Are all passage ways, aisles, exits and fire

escapes clear of obstructions? • Are your driveways clean and clear? • Are extension leads and air hoses put away after

use? • Are the waste bins kept in their proper place?

If you answered yes to all the above questions then you should consider your work place a safe place to work in.

2. Do you take care in the use and storing of hand tools?

Yes No • Do you take care to select the correct type

and size of tool for use? • Do you check the condition of your tools prior

to use? • Do you put away hand tools after use? • Do you maintain your hand tools in good

condition? • Can you extend the leverage of a spanner

by the use of a pipe extension? • Is it safe to carry screw drivers and other sharp

objects in your overalls pockets? • Can you use a spanner as a hammer?

Ask your trainer to check your answers.



Personal protective clothing and equipment

Wear the correct clothing and equipment to protect yourself from possible serious injury.

Some of the safety equipment you may use could include:

• protective clothing

• reinforced footwear

• eye protection safety glasses or goggles

• protective ear muffs or plugs. Noise is measured in decibels (dB for short). The higher the level of decibels the louder the noise. By law, no one is allowed to work in areas where the noise level is more than:

− 115 dB without hearing equipment

− 150 dB at any time (however, hearing loss can be caused from working in areas where the noise is more than 85 dB)

• gloves (variety of choice)

• breathing filters and equipment

• hard hat safety helmet.



Activity 3: What safety clothing and equipment is used in your workplace?

1. What safety clothing and equipment do you use in your workplace?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. Why do you use this safety equipment?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. When should hearing protection be used?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. What is the noise (dB) level in your workplace?

____________________________________________________

____________________________________________________

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



Handling lubricating oil and greases

When changing lubricating oils, ensure that the correct type and grade are used. Use only those recommended by the vehicle manufacturer.

Be careful when draining oil from a hot engine or a hot transmission. It could severely scald you.

When handling hydraulic brake fluid, avoid spilling it on your vehicle paint work. If some is spilt, wipe it off immediately and thoroughly wash the area with water. Replace the lid on the brake fluid after use to keep out moisture.

Be careful not to mix or substitute gear oils. Refer to manufacturer’s specifications.



Activity 4: What should you do prior to replacing oils in your vehicle?

1. Before substituting oils in your vehicle, what should be checked?

____________________________________________________

____________________________________________________

2. Can you substitute the types of oil you use in the various parts of your vehicle for cheaper low grade oils?

Yes No

If No, why not? What may be the result?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. These are just a few of the problems that could occur with oil substitution. Can you name other examples of damage that may result?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Manual lifting

Manual lifting and carrying can subject the body to great strain and frequently causes accidents. It results in serious and permanent back injury if done incorrectly. These injuries often accumulate over a period of time.

To prevent injuries resulting from lifting and carrying objects:

• use suitable mechanical equipment whenever possible

• use appropriate protective equipment

• learn the correct method of lifting and carrying

• ask others to help you lift or carry large or awkward packages.

Compressed air and air tools

Compressed air is extensively used in workshops to operate air tools, such as:

• wrenches

• drills

• grinders

• sanders

• hoists

• tyre bead breakers

• air jacks

• grease guns.

It is also used for parts cleaning, tyre inflation and many other purposes.

Great care must be taken in handling compressed air tools as air can be forced into the body with serious results.

Safety tip

It is dangerous to guide high pressure grease guns onto grease nipples with your fingers. The high pressure could inject grease into your hand or fingers causing them to swell or become infected.



Activity 5: Describe safe operation of compressed air tools

Do you use compressed air to operate tools and equipment in your work place? Make a list of those tools and equipment you use and any safety rules that apply in their use.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Basic hand tools

Care in the use of hand tools

Hand tools can cause accidents when an incorrect size or a defective tool is used. Never use a tool carelessly as injury may result from poor use.

• Be trained in the safe and correct use of all hand tools.

• Make sure you select the correct type and size of tool for the job.

• Check the condition of any tool before you use it.

• Do not use tools that are worn or damaged.

• Maintain tools in good condition and remember that cutting tools need to be sharp to be safe.

• Make sure you use each tool in the correct manner.

• Replace tools on shadow boards or in their correct place when you are not using them.

• Do not use a hammer to assist the turning movement of a spanner.

• Do not extend spanners with a length of pipe or other means to increase leverage.

• Do not strike a hardened surface (ball, race, etc.) with a hammer, as one or both surfaces may chip and fly off.

• Do not use spanners or tools that are coated with grease or oil.

• Do not carry screwdrivers, chisels or pointed tools in the pockets of overalls, etc. They are dangerous in the event of a fall.

• Do not use a spanner as a hammer.

Maintenance of tools and equipment

The life of most tools and equipment will be reduced if they are used and stored in dirty conditions. Regular cleaning is essential and correct storage will safe guard against damage or loss.

Some tools have edges and points which must be kept sharpened to allow them to perform the task for which they were designed.



Discard any damaged tools in accordance with company policy prior to storing. Record details of discarded tools.



Workshop tools

Spanners

Spanners are:

• used for turning thread fasteners

• made with jaws or openings that fit square or hexagonal nuts and bolts and screw heads

• made of high tensile or alloy steel

• drop-‐forged and heat treated for strength

• given a smooth surface finish for ease of gripping.

Spanners vary considerably in shape to provide ease of operation under different conditions. There are four basic types:

Open end spanners

Tube or box spanners

Socket spanners



Ring spanners

The correct spanner to use is the one that:

• fits exactly

• allows for easy use

• will allow the job to be done safely and efficiently.

Importance of correct fit

It is dangerous for you to use a spanner that does not fit correctly. It could result in you injuring yourself and damaging the spanner and nut.

To fit exactly, a spanner must be:

• the correct size

• placed correctly on the nut or bolt head

• in good condition.

Inspection of spanners

Always check the condition of a spanner before you use it. Look for any defect that could cause the spanner to slip under pressure.

Adjustable wrenches

Most common types of adjustable spanners are similar to open end spanners, but they have one moveable jaw.

Adjustable spanners are convenient for use where a full kit of spanners cannot be carried about, for example on maintenance work.

Always turn the adjustable wrench in the direction of the moveable jaw to reduce strain on the wrench.



Hammers

There are many different types of hammers and each is designed for a specific purpose.

All of them can be classed by their head type under two groups, namely the hard head and soft head.

The most common of the hard head types are the ball peen hammer, claw hammer and the sledge hammer.

The most common of the soft head type are those with renewable faces (tips) made from brass and plastic.

The mallet belongs to the hammer family. Its head is very soft and much larger than the forged steel hammer head. It may consist of rubber head mallet and the rawhide head mallet.

Safety tip

Wear safety glasses when using a hammer in a situation where particles could fly from the hammer head or the part being hit.

Oil filter remover

An oil filter remover may be:

• fixed type

• a contracting type:

− either a band or a strap.

An oil filter remover is used to loosen a spin-‐on type oil filter.



Screwdrivers

Screwdrivers are used to tighten or loosen screws and:

• have ends which are shaped for slotted or recessed head

• have blades made of hardened and tempered carbon or alloy steel

• have handles made of wood, plastic or metal

• are given names by length of blade and width of its this includes standard and Phillips head.

Pliers

Pliers are:

• hand tools

• made in many shapes and sizes

• for general or special purpose mechanical trade work

• made of high carbon steel that is forged, machined and heat treated

• made with jaw shapes designed for cutting, holding, twisting, gripping, pulling, pushing and turning

• tools which use levers to gain a mechanical advantage

• available many shapes and types such as:

− combination

− multi-‐grip

− locking or vice

− side cutting

− circlip

− needle-‐point.



Activity 6: Select a range of spanners from your tool board or box

1. From your tool board select the following types of spanners and ask your trainer if you selected correctly: • open ender spanner • ring spanner • combination spanner • half moon spanner • flare nut spanner • socket and ratchet driver.

2. Select the following types of pliers and ask your trainer if you selected correctly: • combination • multi-grip • locking or vice grip • side cutting • circlip.

3. Select a flat screw driver and a Phillips head screw driver and explain to your trainer what they are used for.

4. Why is it quicker to undo a nut with a socket and ratchet?

____________________________________________________

____________________________________________________

5. Name two important rules in using a spanner safely?

1. _______________________________________________

_________________________________________________

_________________________________________________

2. _______________________________________________

_________________________________________________

_________________________________________________



6. List two important rules in using a screwdriver safely?

1________________________________________________

_________________________________________________

_________________________________________________

2________________________________________________

_________________________________________________

_________________________________________________






Section 2

Perform pre-operational vehicle inspection and checks



Section outline


The importance of vehicle inspection and checks

The types of vehicle checks

Wheels and tyres

Braking system

Vehicle checks

Vehicle control checks



Why is it important to perform pre-operational vehicle inspection and checks?

Before you start this section you are reminded that all work practices must be conducted in a manner which meets the Occupational Health and Safety (OHS) Regulations.

A driving licence permits you to drive (depending on licence class) vehicles ranging from small cars to very large trucks.

As a professional driver you need to appreciate that your safety and the safety of others depends on the proper functioning of your vehicle, as well as your care and skill in driving.

It is your task to make sure that certain inspections are carried out to check that your vehicle is roadworthy and prepared for a day's work or an extended trip.

If, as a result of the inspection, you find something that does not seem right, have it checked more thoroughly by a motor mechanic or report the problem to your trainer.

Record details of this inspection and the action taken in your vehicle log book and report it to your trainer.

If you are responsible for your own vehicle maintenance, get your mechanic to check it. If you have any suspicion that your vehicle is unsafe, do not drive the vehicle until it has been thoroughly checked.



There are two types of vehicle checks you can do

They are daily checks, and weekly or pre-‐trip checks.

1. Daily checks

These are the checks which every driver must know and be able to carry out. They must be performed each day before driving commences, and on long trips and before restarting driving after a meal or rest break. These checks are for:

• general external inspection:

− vehicle posture

− leaks underneath the vehicle

− load security

− turntable is greased and locked (if applicable)

− wheel, rim and tyre damage,

− tightness of wheelnuts

• engine compartment general check:

− visible oil, fuel and water leaks

− fluid levels

− belts and pulleys condition and tension

− loose wires or parts

• vehicle registration and in-‐cab inspection:

− vision and seating/seatbelts

− communication equipment

− cab housekeeping

− tilt-‐cab lock security

• engine start up:

− gauges and warning lights

− minor controls

• systems operation:

− lights

− reflector

− signs

• emergency equipment



• systems operation trailer:

− air tanks

− brakes

− on-‐road check.

2. Weekly or pre-‐trip check

The weekly check includes all the daily checks and others which need to be performed regularly to ensure the safety of your vehicle.

To assist you to perform these checks and inspections systematically, they are divided into five groups:

• general external inspection

• engine compartment inspection

• inside vehicle inspection

• systems operations-‐vehicle stationary

• systems operations-‐vehicle moving.

These weekly or pre-‐trip checks are:

• general external inspection:

− vehicle posture

− leaks

− load

− turntable

− wheels and rims

− tyres

− brake system

− steering system

− suspension system

− fuel system

− exhaust system

− air system (air cleaner)

• engine compartment inspection and general check:

− fluid levels

− electrical system

− belts and pulleys



− air brake compressor

− cooling system

− bonnet locks

• inside vehicle inspection and vehicle entry

− vehicle registration

− emergency and safety equipment

− cab housekeeping

− tilt cab locks

− minor controls

• systems operations -‐ vehicle stationary:

− lights, reflectors and signs

− air tanks

− air suspension

− steering

− clutch

− pedals

− gear shift

• systems operations -‐ vehicle moving including trailer:

− air brakes

− complete vehicle

− trailer system

− adjustment

− hydraulic brakes

− vacuum assisted system

• trailer systems operation:

− brakes

− steering

− on-‐road check.



Important

Check your vehicle operating handbook and manufacturer’s specifications for detailed information regarding settings, adjustments, etc., and for any other checks which are necessary for your particular vehicle.

Any servicing or repairs needed as a result of these checks must only be carried out by a mechanic or other suitably qualified person.



Activity 7: What checks are carried out on your vehicle?

1. How often should you do a simple walk around vehicle check?

____________________________________________________

____________________________________________________

2. What are the two types of driver checks?

1________________________________________________

2________________________________________________

3. Why is it important to carry out these checks?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




General external inspection

The following vehicle checks must be carried out:

• vehicle posture:

− as you walk around the vehicle check that it sits squarely on the ground. Excessive leaning to one side may mean a flat tyre, a shifted or unbalanced load or some problem with the suspension

• leaks:

− during your inspection, check beneath the vehicle for fresh drops of oil, coolant, brake fluid and fuel. Listen also for air leaks from the brake system and air suspension

• load:

− check load security on flat-‐top open-‐loaded vehicle. Make certain the load has not shifted, that the sides, tail gate and lift gate are properly secured and that the tarpaulins and lashings are firm

− on cargo vans make sure that the loading bars and straps are in place so that the load is properly secured and the doors are closed and properly fastened

− if your vehicle carries shipping containers make sure the ‘Twist Locks’ are correctly securing the container to the truck

− make sure that all load related items such as loading/unloading aids, dangerous goods signs, safety equipment and emergency procedures information are correctly stowed or installed

− on a tip-‐truck make sure that the tailgate is closed and locked

• turntable:

− check that the turntable release handle is in the locked position if trailer is connected or open if you are bobtail (without trailer)

− check the jaws are properly locked around kingpin

− check that turntable is greased.



Activity 8: Check your vehicle posture and load security

1. What may be wrong with a vehicle that has a bad lean to one side?

Tick the fault which may cause the problem.

a. flat tyre on one side.

b. a broken spring leaf.

c. an uneven load.

d. truck built that way.

2. Does your company have a policy regarding the repair and replacement of flat tyres?

Yes No

If yes, explain what this policy is.

____________________________________________________

____________________________________________________

3. Why is it necessary to check load security?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. What unloading and loading aids do you use in your company?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



5. How should the load be spread on your truck? (Draw diagrams if necessary)

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Wheels tyres and rims

Ask your trainer to help you with the wheel and tyre checks.

Check that the wheel rims are not bent or damaged. If a multi-‐piece rim using lock rings is found to be damaged, the tyre should be deflated before handling to avoid serious injury. Watch for:

• excessive rust or corrosion build-‐up

• cracks in metal

• bent flanges

• deep rim tool marks on rings or gutter areas

• loose, missing damaged rim drive plates

• matched rim parts.

If new tyres have been fitted check that the locking rings have been properly installed.

Check that all wheel nuts and lugs are correctly fitted and properly tightened (signs of rust around a nut or lug may indicate it is loose).

While checking the tension of the wheel nuts and lugs (check manufacturer’s specifications for torque), make sure that the wheel spiders have not spun in the rims. If this happens the tyre valve can be torn out or damaged.

Wheel and rim type

Drop-‐centre

Tubeless tyres are all mounted on drop-‐centre rims and wheels. The drop-‐centre rim or wheel is of single piece construction and is available in both demountable rim and disc wheel configuration. The drop-‐centre rim or wheel has a 15 degree bead seat for sealing tubeless tyres. The drop-‐centre rim is available in either aluminium or steel.

Two-‐piece convertible rims

The two piece rim consists of a side rim and flatbase rim and is available in the demountable rim or disc wheel configuration. The rim has a 5 degree bead seat for tube type tyres.



Three-‐piece rim

The three piece rim consists of a lock ring, side ring and flatbase type rim. It is available in the demountable rim or disc wheel configuration. The disc wheel is available in aluminium or steel, however, the lock ring and side ring are made of steel in all cases. The rim has a 5 degree bead seat for tube tyre mountings.

Tyres

Check tyre pressures using an accurate gauge. Low pressure on the front wheels can cause heavy steering. Low pressure on rear wheels and trailer wheels is more difficult to detect while driving, particularly with dual tyre assemblies. Inflate to manufacturer’s recommendations.

Badly worn or bald tyres are more likely to puncture or blow out. Lack of tread reduces grip on slippery surfaces and can lead to braking skids, poor steering response and jack knifing. Hydroplaning (skimming on the top of the wet road surface) can also occur on wet roads leading to loss of steering and braking control.

Check the:

• side walls and treads for cuts, bulges, and signs of wear caused by contact with other parts of the vehicle

• tread is not separating from the casing. Remove any stones, nails, glass or other objects which have become wedged in the tread and could puncture or damage the tyre

• valve-‐stems are not damaged or fouling other parts.

You should remove any rocks or other objects wedged between the dual tyres or between the wheel and brake drum, objects wedged between tyres can cause serious tyre damage or failure. If pressure is low in either or both dual tyres and they are touching, the tyres may overheat and catch fire.

Change damaged wheel or tyre

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 found.



Activity 9: Identify tyre and rim safety

1. What can happen if you operate your tyres below the recommended tyre pressure?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. If you discovered a cracked locking ring on a tyre that was over inflated, what would you do?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. Obtain from your trainer a tyre tread depth gauge. Measure the tread depth on four of your tyres and list these depths. Check them against the tread depths of new tyres.

____________________________________________________

____________________________________________________

4. What could cause a tyre to catch alight?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



5. Hydroplaning most commonly occurs (tick your answer)

a. as a result of oil loss

b. with new tyres

c. because the vehicle is overloaded

d. with worn tyres on very wet roads

6. What type of rims do you have on your vehicle?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Braking systems

Brake drums

• check them for signs of overheating, cracks or damage

• check mechanical brake linkage for wear (grease if necessary).

Air systems

• check that brake chambers and other parts are securely attached, the linkage and hoses are properly connected and showing no sign of contact with other parts

• drain water from wet tank daily.

Hydraulic systems

• check that the hydraulic hoses are not touching other parts or leaking. Look for visible signs of fluid leakage.

On some vehicles (particularly Tilt Cabs) some of these brake checks may be carried out more easily as part of the engine compartment inspection.

Steering system

Check the following:

• steering gear box for oil leaks, the steering gear box mounting bolts and steering arm for signs of looseness

• parts of the steering linkage are properly attached; also check for signs of wear or damage due to contact with other parts

• power steering hoses and other power steering parts these parts should be checked for signs of leakage, wear or damage due to contact with other parts.

Suspension


• suspension linkage, spring brackets and spring pins for loose connections

• U-‐bolts and torque arms for looseness, cracks, bends or missing parts

• frame for cracks around the attachment points



• rubber bushing for wear or damage

• frame for signs of wear or damage due to contact between suspension parts and the body

• leaf springs for leaves which are broken, missing or have shifted (missing spring cups will allow leaves to twist out from their proper position)

• air suspension bellows and air lines for signs of contact with other parts or damage (leaks will be checked after starting the engine)

• adjustable axles and that the locking pins are all properly in place and are correctly secured by safety clamps

• shock absorbers for leaks or damage; check mountings for looseness and the rubber bushes for wear.

Fuel systems

• Check the fuel tanks to make sure these are properly secured and not damaged or leaking and;

− tank caps are properly fitted

− fuel levels are topped up

• fuel lines and filters to make sure they:

− are secure

− are not leaking

− are correctly positioned away from the hot exhaust and danger of entanglement with other objects

− that fuel filters do not have excessive water or wax present.

Exhaust systems

Check that the muffler and exhaust pipes are properly supported and not leaking, and that all hoses and other attached parts are secure and in good condition. Make sure fuel lines, electrical cables, or any combustible materials are not close enough to the exhaust system to cause any risk of fire or damage.



Activity 10: Identify vehicle faults

1. What could happen to hoses that are in contact with other vehicle parts?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. Why is it important to check for oil and fuel leaks?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. Can you name other examples of vehicle faults? Write these below.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. What could happen if fuel lines are leaking near a hot exhaust?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Engine compartment inspection

In most vehicles an engine compartment inspection will involve lifting the bonnet. However, in some forward control vehicles, access to the engine compartment is gained by tilting the cab forward.

General check

After opening the engine compartment, you should carry out the following checks for damage or missing parts and signs of improper servicing:

• leaks:

− check for signs of oil, coolant, fuel or hydraulic fluid leaks

− check around the manifold and exhaust system for signs of exhaust gas leaks

• check and top up if necessary the fluid and oil levels in the:

− engine

− automatic transmission

− power steering

− air compressor

− fuel injection pump (if not lubricated by the engine system).

Electrical system


• battery is properly secured and that the terminals are tight and free of corrosion

• distilled water in battery; top up if necessary to the recommended level

• wiring to make sure that all cables and wiring are properly secured and that all terminals are firmly connected. If the vehicle has spark plugs, pay particular attention to the high tension wiring and parts. They should be kept clean and dry.

Belts and pulleys


• the condition of belts on the following equipment, and that they are all in place and in good order:

− alternator (or generator)



− water pump

− air compressor

− power steering pump

− conditioner (Note some parts use twin belts)

• belts for showing signs of cracking or fraying and replace

• tension of all belts is correct.

Cooling system


• the radiator is not blocked by insects or grass seeds and that the radiator shroud is secure and undamaged

• the radiator shutters (if fitted) are not damaged or seized

• the fan for damaged, bent or loose blades and worn bearings; make sure all other parts are clear of the blades

• all coolant hoses for cracks or weakness and for leaks at the connections

• top up radiator with coolant if required.

Safety tip

Extreme care must be taken when checking radiators.

The modern engine cooling system operates at a pressure ranging from 40 to 100 kPa. Sudden release of the pressure from an engine at near operating temperature causes the coolant to immediately boil, spraying steam and boiling coolant over the person releasing the pressure. This can cause severe scalding to the face, hands and body.



Activity 11: Check the oil in your vehicle

1. Do this activity with the help of your trainer. Describe to your trainer the process of checking engine oil in your vehicle. Look up your Manufacturer's manual and find out the type, grade and amount of oil your vehicle requires for a refill after draining.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. How do you check your transmission oil level?

Are there any special requirements?

____________________________________________________

____________________________________________________

3. Why is it best to check your radiator coolant level when the engine is cool?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. Why is it important to maintain a tight well adjusted alternator belt?

____________________________________________________

____________________________________________________

____________________________________________________



Bonnet locks

Check that the bonnet locks are properly secured and the bonnet safety catches work.

Inside vehicle inspection

In this part of your vehicle inspection, check:

• the controls for correct operation and settings

• the vehicle for safe, uncluttered visibility

• the emergency equipment required in the vehicle

• start the engine.

Vehicle entry

If you have a ladder or step, check that grab handles or rails are secure. Check that the doors close properly and latch securely.

Vehicle registration

Check that the vehicle registration has not expired.

Emergency equipment

Check that you have all the necessary emergency and safety equipment required by legislation and company policy, and that it is in good condition. Your equipment should include the following:

• fire extinguishers:

− that you have the required number and correct type for your particular cargo, and they are fully charged

• emergency reflectors and lamps:

− check that you have at least three emergency reflectors, if you have emergency lamps, check their condition

• First Aid kit:

− if a First Aid kit is provided, check that it is complete and correctly stowed

• spares and tools:

− check that you have spare fuses, light globes and tools such as a jack and wheel wrench

− snow chains (if appropriate).



If you carry dangerous goods make certain you are equipped with the legislative required equipment.

Suitable portable fire extinguishers suitable for different kinds of small fires

Type of extinguisher Type of fuel

Water Wood, paper, textiles, rubbish, etc

Foam Wood, paper, textiles, rubbish etc

Flammable liquids

Cooking oils and fats

Wet chemicals Wood, paper, textiles, rubbish, etc

Flammable liquids


Live electrical equipment

Carbon Dioxide Wood, paper, textiles, rubbish, etc

Flammable liquids



Powder Wood, paper, textiles, rubbish, etc

Flammable liquids



BCF

Ozone depleting special permit required from Jan 1/96

Wood, paper, textiles, rubbish, etc

Flammable liquids


Vaporising liquid Wood, paper, textiles, rubbish, etc

Flammable liquids




Activity 12: What type of fire extinguisher do you carry in your truck?

1. What type of fire extinguishers are you required to have in your truck?

____________________________________________________

____________________________________________________

2. Ask your trainer to explain what fire extinguishers are carried in the workplace vehicles. List these below and explain what they are used for.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. Does your First Aid kit contain the items listed here?

Add any items that have been missed. a. Bandages b. Band aids c. Eye wash glass and eye wash solution d. Tourniquet e. Burn cream f. Antiseptic g. First aid book h. Accident report forms

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Vision and seating

Clean all windows and mirrors, while cleaning, check them for cracks, scratches or pitting. As you clean the windscreen clean the wiper blades and check their condition. With the windscreen wet, you can check wiper operation.

Adjust the seat and the driving mirrors to suit your driving position, then check the seat belt.

Engine start up

Check that the parking brake is on and the transmission is in neutral. Pressing the clutch pedal down eases the load on the starter. Set the engine shut down knob to the ‘RUN’ position.

Start the engine and allow it to idle until correct oil pressure is registered by the oil pressure gauge. If the oil pressure does not register within 5 seconds, switch off the engine and try to determine the fault.

Do not over rev the engine on start up or while cold as it takes some time for the oil to reach all parts and for those parts to warm up to their proper working temperature.

With the engine running, check that all instruments and gauges are working and that the readings are within normal limits. That is:

• oil pressure gauge should begin to register within 5 seconds of starting the engine and then rise to normal pressure

• voltmeter should show a gradual increase from initial starting voltage to normal operating voltage

• coolant and oil temperature gauges should gradually rise to normal range

• oil, coolant and charge working lights should switch off within the first few seconds of start up

• if the vehicle is fitted with air brakes, they should also be checked.

Having allowed the engine to run during the preceding checks, it may now be shut down. To prevent damage to turbo charger bearings due to oil starvation, do not shut down a turbo charged engine until it has been running for at least 5 minutes after a cold start. Make sure the parking brake is applied.



Note the air pressure reading when the engine is switched off. This pressure should be checked again after the vehicle has been standing for about ten minutes. Do not operate the brakes during this time. Pressure loss after ten minutes should not be more than ten kPa. Listen for air leaks as you move around the vehicle completing other checks.



Activity 13: What is your vehicle oil pressure

1. Use your manufacturer’s manual to find what oil pressure your pressure gauge should register. Show this figure below.

____________________________________________________

____________________________________________________

2. Ask your trainer what you should do if your vehicle oil pressure does not meet the manufacturer’s recommendations? List comments below.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Vehicle housekeeping

Remove any rubbish from inside the vehicle. Make sure all equipment is properly stowed. Remove papers and books from the top of the dashboard.

Tilt cab locks

Check that the tilt cab locks are properly secured and the tilt cab safety locks work.

Minor controls

Check the following controls:

• switches and warning lights for correct settings and to make sure they are all working

• windscreen wipers and washers, making sure windscreen is wet when testing wipers

• horn

• turn indicators, check switch operation, warning light and buzzer

• head and parking lights, check switch operation and high beam indicator light

• heater, demister, air conditioner; check operation of controls and units

• other warning lights not already checked (e.g. oil pressure).

Check the electrical system

For the next part of this inspection you should ask your trainer for assistance.

Lights, reflectors and signs on your vehicle should be:

• clean

• securely attached

• clearly visible

• check the following:

− red and yellow marker plates (if required)

− dangerous goods labels correctly displayed and readable

• check that the following lights are all in good order:

− headlights



− parking lights

− tail lights

− number plate light

− brake lights and warning buzzer

− turning lights and warning buzzer

− hazard warning lights

− running lights.

Remember to turn the ignition key and all switches ‘OFF’ afterwards.



Activity 14: Change indicator globe on your vehicle

Can you change the indicator globes on your vehicle? Ask the mechanic to show you how.



Activity 15: Check the following controls in your vehicle

With the help of your trainer check the following controls in your vehicle. Tick if they are working correctly.

• windscreen wipers and washers

• head lights

• parking lights

• high beam indicator switch

• horn

• heater

• demister

• air conditioner

• oil pressure light

• alternator light

• brake light

• indicators front/rear

• reversing (warning) buzzer

If a control is not working correctly have the fault fixed by your mechanic, or fix it yourself and record the details in your service log book.



Section 3

Undertake post-start up vehicle checks



Section outline


Air brakes -‐ complete vehicle

Hydraulic brakes

Steering

Transmission

Vehicle pre-‐departure check



Air and hydraulic brakes

Check your vehicle systems with vehicle stationary, then with vehicle moving.

Air brakes-‐complete vehicle

Pressures and times quoted in this section are intended as typical examples only. Check your vehicle operating manual or ask your trainer what the figures should be for your vehicle.

If your vehicle is an articulated or combined unit, steps 1 to 11 should be carried out with the trailer brakes connected.

The following is a step by step procedure which will enable you to carry out a complete weekly or pre-‐trip inspection of your air brake system.

1. Immobilise the vehicle

Park vehicle on firm level ground and apply parking brakes. All wheels on at least one drive axle should be securely chocked, front and rear. During this inspection all brakes will be released. Do not perform this air brake inspection if these conditions cannot be met.

2. Drain all air (wet) each day

Empty all air from the tanks by opening the drain valves. This is done in order to remove condensed moisture (water) from the tanks and to allow checking of other parts in the system.

Water in the system causes corrosion and decreases brake component life. Watch for signs of oil in the drained water. If any oil is present, the compressor may need servicing. Close all drain cocks after the system has been drained.

Brake system manufacturers recommend that air tanks be drained daily.



Activity 16: Park your vehicle and drain the air tanks

Demonstrate to your trainer how to park the vehicle, check the brakes and drain the air tanks. Explain why it is important to drain the air tanks daily.




3. Start engine

Turn the ignition key on. The low pressure warning buzzer and/or light should begin operating continuously. Start the engine and run at fast idle (approximately 1000 rpm) to build up pressure in the reservoirs. While pressure is building, take careful note of the items mentioned in steps 4, 5 and 6.

4. Low pressure warning cut off

The low pressure warning device should continue operating until the air pressure reaches at least 410 kPa.

5. Rate of pressure build up

Check the time taken for the pressure to increase from 350 kPa to 600 kPa. This time will vary from one vehicle to another depending on the tank capacities, type of compressor, and engine speed used. You should record the actual time taken and watch for any change each time you repeat the test (always using the same speed). Have the system checked if:

• the time varies by more than one minute

• on the first time you do this test, the times exceed five minutes (five minutes may be a satisfactory time if tank capacity is large or the engine speed is set low, but have it checked to be sure).

If service and reserve tanks are fed through individual check valves, pressure build-‐up should be steady and equal on both gauges. In other systems where the reserve tank is fed from the service tank through a charging valve, the service gauge will reach a predetermined pressure before the reserve tank begins to build up.

6. Maximum cut-‐off pressure

Check the pressure at which the unloader valve operates and no further pressure build up occurs. This should be at least 690 kPa. If outside this range, have it checked.



Activity 17: What is your vehicle’s low pressure warning cut off?

1. Check your vehicle manufacturer’s manual, compare the low pressure warning cut off. Does the pressure match the example given above? If not, at what pressure does your vehicle warning device cut off?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. How long does it take for your air pressure to build up to the correct operating pressure?

____________________________________________________

____________________________________________________

3. Have you checked to see if the pressure build-up time varies?

Yes No

If No, you should do it now and remember to check it on a regular basis.



7. Release parking or spring brakes

Check that the vehicle is on firm level ground and the wheels are chocked (as in step 1). Release the parking brake, make sure the tractor protection valve is in the ‘normal’ position. This makes sure that all brakes are released including the spring brake if fitted.

8. Pressure loss with system standing

Run the engine until maximum pressure has been reached and then shut it down. While the vehicle stands for five minutes note any drop in pressure (it may help to lightly tap the pressure gauge if it appears to be sticking). If the pressure drop in five minutes exceeds 35 kPa the system should be checked.

Where time permits, this check can be performed more accurately by allowing the vehicle to stand for ten minutes and watching for a pressure drop of no more than 70 kPa.

9. Apply the brakes

Apply the brakes fully by pressing the brake pedal to the floor and holding it there. The pressure drop should not be more than 85 kPa. Excessive pressure drop as the brakes are applied can be due to a fault in the system or may indicate that the brakes need adjusting.

Continue to hold the brakes on for one, or if possible, two minutes. Any further pressure drop should not be faster than 15 kPa per minute for rigid vehicles, or 20 kPa per minute for articulated or combination vehicles. If the above limits are exceeded, have the system checked.

10. Loss of pressure protection

With the engine switched OFF, reduce air pressure in the tanks by repeatedly pumping the brake pedal. The low Air Pressure warning device should begin operating within the range of 280 kPa to 410 kPa and the tractor protector valve should switch from ‘normal’ to ‘emergency’ position within the range 140 kPa to 310 kPa.



Activity 18: Demonstrate for your trainer brake checks 7 to 10

Demonstrate to your trainer the recommended checks as listed in items 7 to 10. These checks are necessary for your safety and for that of other road users. Ask you trainer for feedback on your performance.



11. Apply the parking brakes

Re-‐apply the parking brakes and start the engine to build up full pressure before continuing with your inspection.

Air brakes trailer system

If your vehicle is an articulated unit, steps 1 to 11 should have been carried out with the trailer brakes connected. The following additional steps should also be carried out with these vehicles.

12. Break away application. After ensuring that:

• the vehicle is on firm ground with the wheels chocked (step 1)

• air tanks are fully pressurised

• the tractor protection valve is in the ‘normal’ position

• the trailer brakes are fully released

• the air hoses between the prime mover and trailer is connected.

Split hydraulic brake system with frame -‐ mounted bootsters



Safety tip

Take care when disconnecting air couplings under pressure. Protect your eyes from release of compressed air and hold the coupling parts firmly to prevent them flying apart.

The trailer brakes should immediately and automatically apply. This can be verified by checking for movement of the trailer brakes linkage. This emergency application of the brakes should be capable of holding the vehicle for at least 15 minutes.



Activity 19: Demonstrate safe method of disconnecting air hoses

Demonstrate to your trainer while following good safety procedures, the method of disconnecting the air hoses between your prime mover and the trailer. Remember to protect your eyes from the compressed air.



13. Check Tractor Protection Valve

When the trailer hoses were disconnected, the tractor protection valve should have switched from the ‘normal’ to the ‘emergency’ position and sealed off the prime mover system so no air could escape through the trailer hoses. Some vehicles are fitted with cut off valves on the air couplings which also prevent air loss. If these are fitted, the tractor protection valve may not operate.

Fully apply the foot brake and hold the pedal down. Pressure losses should be no more than those obtained in 9.

Brake system installation -‐ tractor trailer

14. Return system to normal

Re-‐connect the trailer hoses. making sure the air couplings are properly locked. Start the engine and recharge the air tanks. Reset the tractor protection valve to ‘normal’ and apply the parking brakes.



Air brakes adjustment

You will also need to ask your trainer for help. The procedure which follows is designed to assist you to check brake adjustment. If adjustment is required it must only be done by a qualified person.

Push-‐rod movement

With the air tanks fully charged and the parking brakes released, note the movement of the brake chamber push-‐rod for one of the wheels as your assistant applies and releases the foot brake. Total movement should not be more than the distance specified in the manual.

Safety tip

Keep you fingers out of the linkage when carrying out this check.

Repeat the check for each of the other wheels. If push-‐rod movement varies greatly from one wheel to another or exceeds specifications, have the brakes checked to see if they are working or need adjusting.



Activity 20: Check the protection valve and return the system to normal

With the assistance of your trainer check the tractor protection valve and return the system to normal.

1. From the manufacturer’s manual, find out what your vehicle brake cylinder push-rod movement should be on each wheel. List the figures below for future reference.

____________________________________________________

____________________________________________________

____________________________________________________

2. With the assistance of your trainer check the brake cylinder push-rod movement on your vehicle, compare these with the manufacturer’s recommendations.

____________________________________________________

____________________________________________________

____________________________________________________




Hydraulic brakes

If the parking brake is not mounted on the transmission it will need to be released for this check so chock the wheels.

With the engine running, release the parking brake and apply the foot brake normally. If the pedal moves more than half-‐way down, adjustment or bleeding of the system is required. The need to bleed the air from the system may be indicated if the pedal feels soft or ‘spongy’ rather than firm. Re-‐apply the parking brake after this check.

Pedal travel firmness

Slow application check, apply the foot brake very slowly taking about 15 seconds to achieve full pedal travel. If the pedal goes all the way to the floor or noticeably further than usual, hydraulic seals in the system may be leaking. Have the system checked.

Maximising pressure check, with the engine running, rapidly pump the pedal three times, then apply brakes with the maximum force possible and hold the application for about five seconds. If the pedal moves further down during this time, service is required.

The previous two checks do not apply to all-‐over hydraulic systems.

Vacuum assisted system

For vacuum assisted brakes, first inspect the brakes as explained in the previous section, ‘Hydraulic brakes,’ then carry out the following additional checks of the vacuum system:

• run the engine until maximum vacuum is reached in the vacuum reservoir

• vacuum loss brakes are applied with the engine switched off, fully apply the brakes and note the rate of vacuum loss (tap the gauge if the needle is sticking). If the vacuum is lost at a rate of more than 12 mm per minute the system should be checked

• with the engine switched off, pump the brakes until the low vacuum, warning signal operates. If the signal does not operate before the pressure drops below 200 mm, the system should be checked

• check that all hoses are properly secured and in good condition. Check that the air filter on the vacuum assistance unit is not blocked and correctly fitted.



Activity 21: Demonstrate for your trainer the check to prove the correct operation of your brake vacuum system

Demonstrate to your trainer the checks necessary to prove the correct operation of your brake vacuum assisted system. Carry out the check on your vehicle.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

Continue the demonstration by checking: • system operation with the vehicle moving • with the trailer attached • parking brakes • steering • on road check completed after driving for approximately 50

kilometres.




System operation-‐vehicle moving

In this final part of your vehicle inspection the vehicle will need to be driven. Seek the assistance of your trainer to carry out these checks.

Before starting you should apply the parking brake, remove the wheel chocks, (if in place), and check that the surrounding area is clear of traffic and other obstructions.

Trailer (if attached)

Release all brakes on the vehicle and gently drive the vehicle forwards about one metre. Stop the vehicle, apply the trailer brake only and try to move off again. The vehicle should not move. If it does, check that the air lines are all connected correctly and repeat the test. If the trailer brakes still do not work, do not drive the vehicle until the fault is repaired.

Parking brakes

With all brakes released, gently drive the vehicle forward about one metre. Stop the vehicle, firmly apply the parking brakes and gently try to move off again. The vehicle should not move. If it does, the parking brake should be checked before the vehicle is driven.

Service brakes

Drive the vehicle forward in first gear at about 5 km/h (walking pace) and then apply the foot brakes as hard as you would in an emergency. If the brakes pull to one side, respond sluggishly or feel unusual in any way they should be checked before driving the vehicle.

Air suspension

After the air pressure has built up, check that the bellows are supporting the vehicle and your vehicle is level. Make sure that the bellows are not in contact with other parts, and not damaged. Listen for air leaks in the system.

Steering

Ask your trainer to help you check your vehicle steering system.

With the front wheels in a straight ahead position, check the free play by turning the steering one way and then the other way, checking for loose play.



If the vehicle is equipped with power steering, these checks may be carried out with the engine running provided the parking brake is applied and the rear wheels are chocked.

While carrying out these checks, listen for any unusual noise from the power steering pump.

Drive vehicle forward slowly at no more than 5km/h, turn steering wheel to right full lock then left full lock. Check anything unusual, particularly any strange noises, scrapes or knocks.



Activity 22: Check the steering on your vehicle

Check the following with the assistance of your trainer:

Yes No • is there free play in your steering? • is there looseness in steering joints? • are there unusual noises in steering pump? • are there air leaks in the air system?

If you answered No to all of the above then your steering system requires no further action. If you answered Yes to any of the above have your vehicle checked by your mechanic.



Clutch

Check the free play of your clutch by pushing in the pedal until a slight resistance is felt. Normal free play is between 5 cm and 25 cm.

Transmission

With the engine running and the clutch pedal held down, check that the gear lever and other transmission controls operate properly.

Pedals

Check that the rubber pads are properly fitted and in good order. In particular make sure to press the accelerator firmly to the floor (with the engine switched OFF) checking that it shows no sign of sticking or jamming.



Activity 23: Demonstrate to your trainer the operation of your clutch pedal to check for free play

Demonstrate to your trainer the checks necessary to show that the clutch has no free play and the transmission controls are operating correctly.

Are all the pedal pad rubbers properly fitted and in good order?

Yes No

If No, what should you do to correct the problem?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Turn-‐table coupling

Check by gently driving forward and then gently reversing, if there seems to be any abnormal movement in the coupling. Find out why, and have the fault corrected.

On road check

After driving the first 50 kilometres of a trip, stop in a safe place away from traffic flow and briefly check around the vehicle. For example, you should check the temperature of the tyres, hubs and brake drums. A high temperature could indicate an under inflated tyre, a binding brake or faulty wheel bearing. Check for oil, water or other leaks. Make sure the load is still secure.



Activity 24: Carry out a vehicle pre-departure check

Carry out a vehicle pre-departure check. Use the checklist on the following pages. Ask your trainer to assist you.

Vehicle pre-departure check

Date: ________________________________________________ Vehicle Registration Number: ____________________________ Inspected by:__________________________________________ Under bonnet OK Product added Details Engine oil Coolant Fuel Clutch fluid Brake fluid Screen wash fluid Ancillary drive belts

Inside vehicle before starting engine

Immediate response

Faulty response

Oil pressure gauge Alternator gauge Air pressure gauge Fuel quantity gauge Other gauge(s) Parking brake on

Inside vehicle start engine OK Unfit/stop engine Oil pressure engine Alternator Air pressure Windscreen wipers Windscreen washers




Inside vehicle turn on lights Fit Details Headlights - low beam Headlights - high beam Hazard lights Visual rear brake

Right front Fit Details

Right front tyre - appearance/rebound - wall damage - abnormal tread wear

Right front wheel - nuts/wedges tight

Right front indicators - regular blinking - clearly visible

Centre front Fit Details Headlight high/low both on even Park lights - clearly visible Clearance lights - clearly visible Plates/signs - present/legible Windscreen - clear vision

Oil leaks - weeps - drips - pools

Exhaust leaks - visible emissions - noise leaks

Vehicle posture - chassis even on wheels




Left front Fit Details

Left front tyre - appearance/rebound - wall damage - abnormal tread wear

Left front wheel - nuts/wedges tight

Left front indicator - regular blinking - clearly visible

Left lockers/door(s)-latches functional

Left side window(s)-clear visibility

Cab tilt lock-functional and locked

Spare wheel - tread - pressure - security

Wheel change tools - jack - stand - socket - wrench - bar

Warning triangles Warning signs

Accessory tools - as per company requirements



Left rear Fit Details

Left rear tyres(s) - appearance/rebound - wall damage - abnormal tread wear

Left rear wheel(s) - nuts/wedges tight

Wheel guard/mud flaps


Centre rear Fit Details Tail lights - clearly visible Brake lights - clearly visible Indicator lights - clearly visible Plates/signs - present/legible

Oil leaks - weeps - drips - pools

Exhaust leaks - visible emissions - along tailpipe

Vehicle posture - chassis even with wheels

Right rear Fit Details

Right rear tyre(s) - appearance/rebound - wall damage - abnormal tread wear

Right rear wheel(s) - nuts/wedges tight

Wheel guard/mudflaps Air wet tank Fit Details

Service air wet tank - emissions quality




Coupling equipment Fit Details

Trailer chock(s) - in place - secure

Air hose(s) - connected securely - visible damage - noise leaks - secure from other moving parts

Electrical cable(s) - connected securely - visible damage - secure from other moving parts - not worn

Turntable jaws - locked

Skid plate - not worn - bent - cracked

King pin - not worn - bent - cracked - no excessive movement




Return to inside vehicle Fit Details Right side door(s)

- latches functional

Right side window(s) - opening functional - clearly visible

Service brakes functional Warning horn functional

Seat adjustment - personal requirement - check adjustment - lock secure

Rear view mirrors - adequate rear vision

Registration certificate - current registration and licence

Inside vehicle equipment - First Aid kit - log book - invoices - carte notes - maps etc

Passenger comforts - magazines - pillows - videos, CDs - rest room supplies

Dangerous goods safety equipment to meet legislative requirements



Section 4

Clean your vehicle and trailer



Section outline


Clean your vehicle and trailer

Maintenance of cleaning equipment

Storage of cleaning equipment



Clean your vehicle/trailer

Why is it important to have a clean vehicle/trailer?

Having a clean vehicle/trailer is important for many reasons ranging from vehicle/trailer safety to a better public image. A clean vehicle/trailer will:

• improve company's image or your own image as the owner of that vehicle/trailer

• promotes company/owner image because it allows the public/client to clearly see the company/owner name on the vehicle/trailer

• improves safety because the vehicle is free from rubbish, dirt and obstructions

• increases the life and improves the condition of the vehicle/trailer as dirt and chemicals can cause rust or damage to fittings, surfaces and seals.



Activity 25: Describe how a clean vehicle plays an important part in your company

1. In what way does having a clean vehicle improve safety?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. How does dirt and grime reduce the life of equipment?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



3. How do you maintain the painted surfaces on your vehicle/trailer?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. What can happen if your company has a low company image?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

5. Why should you care about your company image?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Legislative requirements for cleaning area

By law, companies must have a special area where vehicles/trailers are cleaned, so that pollutants do not flow into storm water drains.

The area for cleaning vehicles/trailers must:

• have a roof to stop storm water flooding the separator pit

• be surrounded by a concrete border high enough to prevent spilling of contaminated water

• have a separator pit for separating:

− oil

− petrol

− diesel

− detergent

− other pollutants

• have a power supply for the use of cleaning equipment such as:

− vacuum cleaners

− steam cleaners

− high pressure cleaners

• have a water supply which may consist of hot and cold water

• be safely located so that the cleaning of vehicle/trailer does not get in the way of other company operations.



Activity 26: Safety features with car wash operation

1. Why does a separator pit help to protect the environment?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. Why is it important for the cleaning area to be away from other work activities?

____________________________________________________

____________________________________________________

3. What special precautions must you take when using electrical equipment, for example, a vacuum cleaner in a wet area?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

4. Why is the combination of water and electricity dangerous?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



5. Use the check list to make certain your cleaning area meets the legal requirements for vehicle/trailer cleaning area.

Cleaning area checklist

Does your area have? Yes No

- a roof to stop flooding by stormwater

- a concrete border to stop spillage and overflow

- a separator pit to trap polluted water

- a convenient water supply

- a safe access to power for cleaning equipment

- a cleaning area safely located away from other work activities.

If your answer to all of these questions is YES then you have a vehicle washing area which meets the legal requirements for washing vehicles/trailers.

Before you start cleaning your vehicle/trailer you need to make sure that the vehicle/trailer is parked securely.

Ask your trainer to help you park the vehicle/trailer in the designated cleaning area.

Put the handbrake on to make sure the vehicle/trailer cannot move if it is accidentally knocked. If the vehicle is equipped with a Bowden cable always leave the Bowden cable stop control out when the vehicle is parked.



Activity 27: Special requirements in vehicle cleaning

1. Does your company have any special requirements or conditions for vehicle/trailer cleaning?

Yes No

If Yes, list these requirements.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. List five important things you need to do before you start to clean your vehicle/trailer.

1. _______________________________________________

2. _______________________________________________

3. _______________________________________________

4. _______________________________________________

5. _______________________________________________

3. What could happen if you wash or clean your vehicle/trailer in an area that is not meant to be used for cleaning vehicle/trailer?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



4. What could happen if you do not park your vehicle/trailer properly?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Equipment and materials used in vehicle/trailer cleaning

A wide range of equipment and materials can be used to assist with the task of vehicle/trailer cleaning. Some examples are:

• protective clothing

• bucket, brooms, brushes and squeegee

• chamois rags and dusters

• steam cleaning/pressure cleaner

• ladder and steps

• vacuum cleaner and power source

• water hose and water source

• various cleaning agents that are recommended by the manufacturer of your vehicle/trailer and will not damage or harm the vehicle/trailer's surfaces.



Activity 28: What items would you use to help you clean your vehicle and trailer?

List the items that you would use to help you clean your vehicle/trailer.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Storage of cleaning equipment and materials

Cleaning equipment and materials should be stored in a clearly marked area. This is necessary so that:

• everybody knows where they found

• cleaning equipment and materials do not become physical hazards

• cleaning agents, chemicals and sharp instruments are kept out of the way.

The area should be safe to move around in so that removing and returning cleaning equipment and materials is safe and easy. Storage areas should be made safe by the use of:

• tool racks

• cabinets

• sheds

• indoor and outdoor areas for easy access.

Storage areas should include operating manuals for all cleaning materials and machinery/equipment held in the store.

The area should also house any documents for recording the use of the cleaning materials and any spare parts that must be filled in or checked each time you use the equipment in that area.

The safe and proper storage of equipment and the use of materials storage facilities is called good housekeeping.

Housekeeping can be identified as the process used by organisations to maintain a safe, clean and tidy workplace. Poor performance in this area will result in inefficiencies leading to a drop in productivity and safety.

This function is directly linked to Occupational Health and Safety (OHS) regulations which must be followed under federal and state/territory law.



Activity 29: Identify equipment and materials storage facilities

Identify appropriate housekeeping equipment and materials storage facilities in your workplace. Look at the list of cleaning equipment and identify the storage used for each item. Add other cleaning items that may be missing from the list.

Do this task with the help of your trainer.

The storage required for the first item on the list has been completed as an example.

Cleaning item Storage

Brooms or Brushes Stored in cleaner’s cupboard or hung from a rack

Steam or pressure cleaner

Water hose

Rags and dusters

Ladders or steps

Cleaning agents such as chemicals



Safe handling of cleaning equipment and materials

Some of the materials used in cleaning are dangerous if they are not handled or used properly. In some cases specific training may be needed before you can operate the mechanical equipment or use hazardous cleaning substances.

Cleaning machinery/equipment

To safely use or operate cleaning machinery/equipment you should:

• read the instructions on how to use the cleaning machinery/equipment

• check the equipment to make sure it is in good condition

• make sure the electrical switches are not broken or damaged

• make sure electrical cords are not frayed, guards are fitted, etc.

• ask your trainer to show you how to use the equipment if you have never used it before

• obey all safety signs in your work area.

Cleaning products

To safely use cleaning products you should:

• read the warning labels and instructions for use

• know what to do if an accident happens

• ask your trainer to show you how to use cleaning products if you have never used them before

• obey all safety signs in the work area.



Activity 30: What cleaning equipment do you use in your company?

1. What cleaning equipment is used in your company?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

2. Write down what you need to do to use it safely.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. Name a cleaning product that is used in your company?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



4. Write down what you need to do to use it safely.

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

5. What cleaning equipment and materials do you use that can be dangerous if not used properly.

For example: • industrial vacuum cleaner

____________________________________________________

____________________________________________________

____________________________________________________

6. In what way could this equipment and materials be dangerous?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________



Maintenance of cleaning equipment

Electrical equipment needs regular servicing to keep it in good working order.

Equipment used in cleaning such as steam cleaners, or vacuum cleaners can be dangerous if they are not maintained in good condition and serviced regularly.

Manufacturers of electrical equipment will have a suggested maintenance schedule for the equipment they make.

An Equipment Maintenance Check List has been included in the following activities.

Complete the check list with the assistance of your trainer.



Activity 31: Maintain cleaning equipment

1. Why is the maintenance of cleaning equipment necessary?

____________________________________________________

____________________________________________________

____________________________________________________

2. What can happen if cleaning equipment is in poor condition?

____________________________________________________

____________________________________________________

3. How can a company make sure that equipment is properly maintained at the recommended service times?

____________________________________________________

____________________________________________________

____________________________________________________

4. List two pieces of equipment that is used for cleaning in your work place. What do you need to do before and after using that equipment to keep it in good condition?

Equipment:____________________________________________

Maintenance method: ___________________________________

Equipment:____________________________________________

Maintenance method: ___________________________________



Use the checklist below to help you inspect that piece of equipment for damage and wear.

Electrical equipment safety checklist

Tool/Equipment:

Housekeeping job:

Date:

Check Yes No

frayed?

showing exposed wires?

showing burns?

in a knot or kinked?

Is the lead (cable):

damaged in any way?

showing bent pins?

showing burn marks?

wet or damp?

Is the plug:

damaged in any way?

overheating or smelling burnt? Is the tool/equipment:

showing any signs of damage? (e.g.: cracked casing, damaged switch)

WARNING!! If you answered yes to any of these questions, do not use the tool/equipment. Follow your workplace reporting procedure.




Cleaning your vehicle and trailer

When you are cleaning your vehicle/trailer it is a good idea to do it in a logical and systematic order. The most effective and time saving way to clean your vehicle/trailer is in the following order:

• clean the inside of the vehicle

• clean the outside of the vehicle

• clean trailer

• check vehicle/trailer.

Clean the inside of your vehicle in the following order:

1. check prior to opening vehicle doors

2. remove rubbish and dispose in appropriate place

3. stow all equipment such as:

• passenger reading material

• safety information

• invoice books and other stationery

• breakdown equipment

• First Aid chests, dangerous goods

• safety equipment required by law

• videos, music cassettes and CDs.

• sweep/vacuum and dispose of waste

• check and clean passenger rest room facilities

• clean seats, dash board, steering wheel, instrument panel, mats, operating levers, pedals (with a cleaning agent) and replace seat protectors (where applicable)

• clean all interior glass surfaces with approved cleaning agent

• close all windows, door and air vents to prevent dust and water from entering the clean interior

• fill water containers for passenger requirements



• replace soap, hand towels and toilet rolls in bus rest rooms

• check that pillows and blankets are clean and stowed correctly.



Activity 32: What items do you need to stow before washing your vehicle?

1. List four items of equipment that you will need to stow, when cleaning the inside of a vehicle.

1. _______________________________________________

2. _______________________________________________

3. _______________________________________________

4. _______________________________________________

2. What should you do prior to applying cleansing agent to any vehicle surface?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

3. List four items that require cleaning with a cleansing agent (also list the learning agent).

1. _______________________________________________

2. _______________________________________________

3. _______________________________________________

4. _______________________________________________

4. Why is it necessary to close all windows and air vents before cleaning the outside of the vehicle?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Clean the outside of the vehicle

Wash the exterior of the vehicle with a hose in order to remove excess dirt, dust, mud pockets. Paint surfaces can be severely marked by grit particles, washing assists the removal of mud and grime from surfaces. Wash the vehicle sides, top and underneath.

Wash exterior with hose and brush/broom to remove road grime. Apply cleansing agent to water (i.e.: detergent, car wash liquid, according to company policy and manufacturer's recommendation).

Hose exterior of vehicle to remove detergent and chemicals. Chamois dry exterior of vehicle to give a smear free finish. Clean glass and chrome with approved cleaning agent.

Clean trailer

Prior to cleaning trailer you should check that all lashing equipment and tools are properly stowed.

Trailer should be first tidied by:

• removing rubbish from trailer.

• disposing of rubbish in appropriate place

• sweeping trailer.

Clean trailer systematically:

• hose off trailer (top, sides and underneath)

• clean with broom and brush

• apply cleansing agent to water and wash trailer (top, sides and underneath)

• hose off trailer and dry.

Check vehicle/trailer

Examine vehicle and re-‐check the following:

• mirror placement for vision

• windscreen

• washers and wipers

• safety check that brakes are working. If you do not know how to do this ask your trainer to show you how. You should always check a vehicles brakes after cleaning the vehicle.



Maintaining vehicle/trailer cleaning area

It is important that you maintain a clean safe working area. The tasks you need to attend to are:

• clean area of responsibility

• waste removal

• scheduling

• equipment maintenance

• returning and storage of equipment and material

• continuous monitoring to maintain workplace standards

• regular inspection.



Activity 33: Safety first in the workplace

How could accidents be caused by each of the following examples of poor housekeeping?

Example:

• Rubbish, dunnage, surplus lashing equipment and old ropes left in cleaning area?

____________________________________________________

____________________________________________________ • Grease and oil spills in car wash area?

____________________________________________________

____________________________________________________ • Electrical leads trailing across car wash area?

____________________________________________________

____________________________________________________ • Overflowing rubbish bins?

____________________________________________________

____________________________________________________ • Badly maintained equipment?

____________________________________________________

____________________________________________________ • Chemicals and cleaning agents not stored after use?

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________




Waste removal

When considering waste removal, the important things you need to consider are:

• risk from chemical spills

• contamination

• removal of materials used to absorb spillage's etc. these need to be treated under the same rules as the original product

• to manage waste you need to apply the following principles:

− reduce

− re-‐use

− recover

− segregate

− specialised removal

− application of hazardous waste removal regulations and code of practice.

Chemicals in the workplace

More than 2,000 people die each year in Australia because of exposure to chemicals in the workplace. We use chemicals everywhere in our homes as well as at work. They can be in the form of solids, liquids or gases. The only way to work with them safely is to know the right way to use them.

Some people become careless, with many chemicals the damage to health doesn't happen straight away but over time. The effects of the chemical build up in their bodies can cause sickness such as cancer. Don't let this happen to you!

Safety tip

The only safe way to use chemicals is to know what the dangers are with each chemical and follow the procedure or rules for safe handling every time you use them.

Cleaning rags and dusters that can be reused are separated for cleaning. Polluted rags are separated to avoid any possibility of reaction from other chemically polluted rags, these are stored in appropriate waste containers. You should arrange for specialised removal in accordance with company and regulatory requirements.



Activity 34: Clean your vehicle and trailer

Clean your vehicle and trailer.

Stages Steps Activity completed

1. Park vehicle/trailer

• shut down engine • hand brake on • gear lever in neutral • check safety factors:

− the area is clear of obstacles − all equipment is stowed correctly − the vehicle/trailer is not parked

in the way of other workplace operations

− vehicle/trailer parked in designated washing area

• obstructions, personal and distance: − loose refuse, pallets, loading

materials all cleared from the washing area

− check all equipment for faulty electrical switches or cables.

2. Locate cleaning equipment

• in line with company requirements.




3. Clean interior of your vehicle

• safety check before opening vehicle door

• remove rubbish and dispose of in appropriate place

• check all equipment is appropriately stowed

• sweep/vacuum and dispose of waste in appropriate place

• check and clean passenger rest room facilities

• clean interior with cleaning agent: − seats − instrument panel − steering wheel − dashboard instruments − mats − pedals − switches

• replace seat protectors • clean all interior glass with

approved cleaning agent • close all windows, doors and air

vents • fill water containers for passenger

requirements • replace soap, hand towels and

toilet rolls • check pillows and blankets are

clean and stowed correctly.





4. Check cleaning equipment

• check safety factors • check hose and water tap for

damage and supply • turn on water supply • adjust water pressure

appropriate to task.

5. Clean outside of the vehicle

• wash: − roof − right front − left front − centre front − rear.

6. Clean roof of vehicle

• hose roof of vehicle • clean with broom/brush • hose roof until clean.

7. Clean right front of vehicle

• hose outside right front • window, mirror, door, step,

wheel bay, rim, and wheel guard/mudflap

• clean with broom/brush • hose until clean.

8. Clean left front of vehicle

• repeat steps of stage 7.

9. Clean centre front of vehicle

• hose outside of centre front • windscreen, windscreen wipers,

bonnet, grill, numberplate, safety signs and lights





10. Clean rear of vehicle

• hose rear of vehicle • rear window • clean with broom/brush • hose until clean.



11. Apply cleansing agent to outside of vehicle

• safety: − read safety precautions for

cleansing agent − follow manufacturer's

instructions − use correct safety equipment

• apply cleansing agent to: − roof of vehicle − right front − left front − centre front − rear

• replace cleansing agent in appropriate place.

12. Check trailer • locate in cleaning area • brake on • chocked (if necessary) • legs lowered.

13. Secure lashing equipment

• check all lashing equipment and tools are properly stowed.

14. Tidy trailer • remove rubbish from trailer • dispose of rubbish in appropriate

place • sweep trailer.



15. Clean trailer from left front to left rear

• hose trailer from left front to left rear

• chassis, wheels, rims, rear axle, mud flaps, wheel bays, combing rails, tool box, walls, curtains and straps, nose cone, and door


16. Clean trailer from right front to right rear

• repeat steps of stage 15.



17. Clean trailer centre rear

• repeat steps of stage 15, including: − cargo and safety signs − lights − number plates.

18. Apply cleansing agent to trailer

• apply safety factors as in stage 11

• apply cleansing agent to: − left front and left rear − right front and right rear − centre rear − as in stages 15, 16 and 17

• replace cleansing agent in appropriate place.

19. Final clean of vehicle/trailer

• hose clean − roof of vehicle − right front of vehicle − left front of vehicle − centre of vehicle − rear of vehicle − left front to left rear of trailer.



− right front to right rear of trailer.

20. Replace cleaning equipment

• to company requirements • to personal hygiene safety.

21. Return to vehicle • check: − adequate mirror vision − windscreen clean − washers and wipers are

functioning − safety check brakes are

operating.

22. Observe OHS procedures

• observe and implement Occupational Health and Safety practices, during completing all sub-tasks.





Additional resources



Paper based:

• vehicle manufacturer’s guides

• guides to cleaning products and equipment from manufacturers and distributors.



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 3: What safety clothing and equipment is used in your workplace?

By law no one is allowed to work in areas where the noise level is more than:

• 115 dB without hearing protection

• 150 dB at any time.

Activity 4: What should you do prior to replacing oils in your vehicle?

Manufacturer’s specifications

No

If you were to substitute a lower grade motor oil in the engine, it could: • break down under load pressures • separate • oxidise engine parts • gum up your engine • cause your engine to overheat.

If you were to substitute brake fluid, it could: • cause your brakes to fail • overheat.

If you were to substitute transmission fluid, it could: • gum up your transmission • overheat and cause transmission failure • damage transmission seals.



Activity 6: Select a range of spanners from your tool board or box

4. A ratchet is faster because you do not have to remove it after each turn.

5. Turn open-end and ring spanners by pulling on the shank. It is safer to pull on the shank because there is less chance of hitting your knuckles if the spanner or nut gives suddenly.

It is dangerous to use a spanner that does not fit correctly. You could end up injuring yourself and damaging the spanner and the nut.

6. Never hold small work in your hand when using a screwdriver, it could slip and give you a serious injury.

Never rest your hand where a slipping screw driver could injure it.

Activity 7: What checks are carried out on your vehicle?

1. Daily

2. a. Daily

b. Weekly or pre-departure.

3. To make sure your vehicle is roadworthy and prepared for a days work or an extended trip. If, as a result of checks you make you find something that does not seem right, have it checked. Record it in your vehicle log and report it to your trainer for action. If you are responsible for your own vehicle maintenance, get a mechanic to check it.

Activity 8: Check your vehicle posture and load security

1. What may be wrong with a vehicle that has a bad lean to one side? Tick the fault which may cause the problem.

a. flat tyre on one side.

b. a broken spring leaf.

c. an uneven load.

d. truck built that way.



3. You are responsible for getting your cargo to its destination in good condition and without risk to other road users and the general public, that means that it must be correctly loaded and secured firmly on your vehicle.

5. The load should be spread to keep the centre of gravity as low as possible. When the load is stacked, larger and heavier items should be placed at the bottom. Heavy solid items should be ideally placed in the front of light crushable ones.

Activity 9: Identify tyre and rim safety

1. Tyres will show excessive wear on the edges of the tread.

2. Completely deflate tyre prior to demounting. If either rim or rings are damaged or ring appears to be unseated the tyre should be deflated prior to removal from the rim assembly and from the vehicle. Remove valve core to make sure tyre is completely deflated.

4. Running a tyre flat allowing it to build up sufficient heat to cause a fire.

A tyre rubbing on something creating sufficient heat to ignite the tyre.

5. Hydroplaning most commonly occurs (tick your answer)

a. as a result of oil loss

b. with new tyres

c. because the vehicle is overloaded

d. with worn tyres on very wet roads

Activity 10: Identify vehicle faults.

1. The continued contact could fracture or create a hole in the hoses with possible serious consequences to the safe operation of your vehicle

2. Oil and fuel leaks can have serious consequences:

• leaking brake master cylinders can seriously affect the operation of your brakes

• leaking engine could have serious consequences to the operation of your engine



• brake fluid leaks could lead to brake failure

• transmission leaks could lead to gear failure or damage.

4. If not corrected this could lead to a fire and place your truck and yourself in danger.

Activity 16: Park your vehicle and drain the air tanks

1. Park vehicle on firm level ground and apply parking brakes. All wheels on at least one drive axle should be securely chocked, front and rear. During this inspection all brakes will be released. Do not perform this air brake inspection if these conditions cannot be met.

This is done in order to remove condensed moisture (water) from the tanks and to allow checking of other parts in the system.

Activity 20: Check the protection valve and return the system to normal

1. The tractor protection valve is a valve which automatically closes off the air supply to the trailer brakes when pressure drops to an unsafe level (when a trailer brake hose bursts or becomes disconnected). This makes sure that the tractor (prime mover) brakes remain operational but also means that the trailer spring brakes (if so equipped) will come on due to lack of air.

Check the brake air lines and brake hoses for damage or leaks, repair or replace air hoses if necessary. If no damage found reconnect air hoses and recharge the system, check the brake system again. If problem persists seek the assistance of your motor mechanic.

Activity 21: Demonstrate for your trainer the check to prove the correct operation of your brake vacuum system

1. Vacuum system test, start the engine and let it idle for at least one minute. Pump the brake pedal several times then allow the engine to idle for another minute. The gauge should read at least (18 to 21 inches) 450 to 525 cm of vacuum. If the gauge falls below 400 cm have your system checked out by a mechanic.



Activity 23: Demonstrate to your trainer the operation of your clutch pedal to check for free play

2. Replace the clutch pads

Activity 25: Describe how a clean vehicle plays an important part in your company

1. A clean windscreen free of dirt smears allows your wipers to work more efficiently and removing crushed insects gives the driver a much better view with reduced possibility of sun glare being compounded by dust.

Clean headlights, taillights, stoplights, indicator lights and clearance lights make your vehicle easier to see.

Cleaning dirt, mud and road grime from your truck and trailer makes it more visible to other motorists.

2. Dirt, grime and mud allows the build up of rust to commence, it also increase the likelihood of contamination of working components.

Highly technical components such as fuel injector systems, onboard computers. radios and communication systems (to name a few) can be seriously affected by dirt and grime.

3. By regularly cleaning your vehicle with an approved car cleaning chemical and periodically polishing the paint work.

4. A low company image can have serious consequences on a companies ability to gain new business. This problem will accentuate with major companies working towards AS3902 and ISO9002 accreditation. These companies will prefer to do business with other AS3902 and ISO9002 companies. Ask your trainer to explain these terms to you.

5. Maintaining a good company image and being a good employee lets your employer know that you care about your job and the company.



Activity 26: Safety features with car wash operation

1. A separator separates the water from all of the oils, greases and other road grime into a collection tank, this reduces the risk of polluting our rivers and oceans.

2. So that the car cleaning tasks can be carried out in a designated area that will not interfere with the other workplace operations.

3. Make certain that you do not allow electrical flex to dangle in or be in contact with wet areas. That all electrical leads are in good condition and show no signs of wear or damage.

Check that all electrical equipment is earthed.

The source of the power is undamaged and safe to use.

4. Water is a good conductor of electricity.

Activity 27: Special requirements in vehicle cleaning

2. Check the car cleaning area for hazards.

Park and stabilise the vehicle.

Close all windows, doors and air vents to prevent dust and water entering the cleaned interior.

Remove all rubbish and dispose in appropriate place.

Stow all loose equipment.

3. You and/or your company may be prosecuted. You will pollute storm water drains, rivers and the ocean with grease, oil and road grime.

If your vehicle overhangs the car wash area it may be hit by other vehicles. It may be in the way of other workplace activities.

If your trailer is not parked and supported correctly it could accidentally tip forward or sideways, if it overhangs the car wash it could be hit by other workplace or client vehicles.



Activity 31: Maintain cleaning equipment

1. To prevent damage or wear to the equipment that could be hazardous. Regular maintenance will extend the life of the equipment and lessen the chance of equipment failure or breakdown.

2. Equipment in poor condition could be hazardous to the user.

3. By maintaining an equipment service register that details the equipment a schedule (usually based on manufacturer’s recommendations) for servicing periods.

Activity 32: What items do you need to stow before washing your vehicle?

1. • street directory and road maps • invoice books and other stationery • safety equipment required by law • loading and lashing equipment.

2.

Thoroughly hose down the vehicle and remove all harmful road-grime, dust or mud from the paint surfaces as this will scratch and mark the paintwork.

3 • glass • steering wheel • console area and instruments • seats • floor mats.

4.

To prevent water and dust entering the cleaned interior.



Activity 33: Safety first in the workplace

1. Workers could trip over the rubbish and seriously injure themselves.

2. Someone could slip on these spills and seriously injure themselves.

3. Someone could be electrocuted.

4 Workers could trip over the rubbish and seriously injure themselves.

5. Could seriously injure someone.

6. Non stored chemicals can become a health hazard, they can be spilt and if washed down a drain they would pollute the waterways. Toxic gases accidentally leaked into the air would pollute the air and could affect the health of many people in the community. Flammable liquids could explode and seriously injure workers or cause serious damage to property and may even cause death.

Documents

TLIB407C - Carry Out Vehicle Inspection - Learner Guide