TLIB407C

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
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).
© Australian National Training Authority 2003 Page 1

Customised and Developed by Armstrong’s Driver Education P/L June 08 ADELG1032
Planning your learning
It is important to plan your learning before you start because you may
already have some of the knowledge and skills that are covered in this
Learner’s Guide. This might be because:
• you have been working in the industry for some time,
and/or
• you have already completed training in this area.
Together with your supervisor or trainer use the checklists on the
following pages to help you plan your study program. Your answers to
the questions in the checklist will help you work out which sections of
this Learner’s Guide you need to complete.
This Learner’s Guide is written with the idea that learning is made more
relevant when you, the learner, are actually working in the industry.
This means that you will have people within the enterprise who can
show you things, discuss how things are done and answer any
questions you have. Also you can practise what you learn and see how
what you learn is applied in the enterprise.
If you are working through this Learner’s Guide and have not yet found
a job in the industry, you will need to talk to your trainer about doing
work experience or working and learning in some sort of simulated
workplace.
Page 2 © Australian National Training Authority 2003

ADELG1032 Customised and Developed by Armstrong’s Driver Education P/L June 2008
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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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 ________________________________________________
_________________________________________________
_________________________________________________

Guide.


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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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)
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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 Wood, paper, textiles, rubbish, etc
Ozone depleting special Flammable liquids
permit required from
Jan 1/96
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.

Guide.

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.
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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.

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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 Immediate Faulty

engine response 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
- wall damage
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)
- wall damage
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)
- wall damage
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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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
Is the lead (cable): frayed?
showing exposed wires?
showing burns?
in a knot or kinked?
damaged in any way?
Is the plug: showing bent pins?
showing burn marks?
wet or damp?
damaged in any way?
Is the tool/equipment: overheating or smelling burnt?
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.

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________

Guide.

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 • shut down engine
vehicle/trailer • 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 • in line with company requirements.
equipment

Stages Steps Activity

completed
3. Clean interior of • safety check before opening
your vehicle 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.

Stages Steps Activity completed

4. Check cleaning • check safety factors
equipment • check hose and water tap for
damage and supply
• turn on water supply
• adjust water pressure
appropriate to task.
5. Clean outside of • wash:
the vehicle − roof
− right front
− left front
− centre front
− rear.
6. Clean roof of • hose roof of vehicle
vehicle • clean with broom/brush
• hose roof until clean.
7. Clean right front • hose outside right front
of vehicle • window, mirror, door, step,
wheel bay, rim, and wheel
guard/mudflap
• clean with broom/brush
• hose until clean.
8. Clean left front of • repeat steps of stage 7.
vehicle
9. Clean centre front • hose outside of centre front
of vehicle • windscreen, windscreen wipers,
bonnet, grill, numberplate, safety
signs and lights


10. Clean rear of • hose rear of vehicle
vehicle • rear window

11. Apply cleansing • safety:
agent to outside − read safety precautions for
of vehicle 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 • check all lashing equipment and
equipment tools are properly stowed.
14. Tidy trailer • remove rubbish from trailer
• dispose of rubbish in appropriate
place
• sweep trailer.

15. Clean trailer from • hose trailer from left front to left
left front to left rear
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 • repeat steps of stage 15.
right front to right
rear

17. Clean trailer • repeat steps of stage 15,
centre rear including:
− cargo and safety signs
− lights
− number plates.
18. Apply cleansing • apply safety factors as in stage
agent to trailer 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 • hose clean
vehicle/trailer − 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 • to company requirements
equipment • 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 • observe and implement
procedures 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.


TLIB407C - Carry Out Vehicle Inspection - Learner Guide

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

TLIB407C - Carry Out Vehicle Inspection - Learner Guide

Caricato da

Copyright:

Formati disponibili

Carry out vehicle

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

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

What this Learner’s Guide is about

© Australian National Training Authority 2003 Page 1

Planning your learning

Page 2 © Australian National Training Authority 2003

Section 1: Routine maintenance

Are you able to: Yes No

Section 2: Perform pre-operational vehicle

Are you able to: Yes No

Section 3: Undertake post-start up vehicle

Are you able to: Yes No

© Australian National Training Authority 2003 Page 3

manufacturer’s specifications and safety

Section 4: Clean your vehicle and trailer

Are you able to: Yes No

Page 4 © Australian National Training Authority 2003

How you will be assessed

You will be required to:

© Australian National Training Authority 2003 Page 5

Page 6 © Australian National Training Authority 2003

© Australian National Training Authority 2003 Page 7

Areas covered in this section

Safe workshop activities

Personal protective clothing

Basic hand tools

Handle lube oils and greases

Page 8 © Australian National Training Authority 2003

Safe workshop activities

Effects of industrial accidents

Cause of accidents

There are two causes of accidents:

Think about these examples of unsafe acts:

© Australian National Training Authority 2003 Page 9

• distracting others from their work, or allowing yourself to

Page 10 © Australian National Training Authority 2003

Consider these examples of unsafe conditions for the worker:

Avoid unsafe acts

Eliminate unsafe conditions

© Australian National Training Authority 2003 Page 11

Page 12 © Australian National Training Authority 2003

Activity 1: Demonstrate your knowledge on workplace safety

1. What kind of hazards are there in your workplace that may

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

3. Find out what accidents have happened in your workplace and

© Australian National Training Authority 2003 Page 13

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

If Yes, what was done to correct the problem?

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

Example: A lot of people cut their hands because

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

Example: Cluttered walkways and passages.

Page 14 © Australian National Training Authority 2003

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?

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

Ask your trainer to check your answers.

© Australian National Training Authority 2003 Page 15

Personal protective clothing and equipment

Page 16 © Australian National Training Authority 2003

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

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

These weekly or pre-‐trip checks are: