Unit TLIB507C

Carry Out Maintenance of

Vehicles Designed to Carry
Special Loads

Workplace Trainee Workbook

Acknowledgements
TDT Australia Project Team

Precision Consultancy

Dogma Production (cover design)

TDT Australia
Level 1, 351 William Street
West Melbourne VIC 3003

TEL: +61 3 9320 4242

FAX: +61 3 9320 4243

E-mail: tdt@tdtaustralia.com

Website: www.tdtaustralia.com

© Australian National Training Authority (ANTA), 2001

All rights reserved. This work has been produced initially with the assistance of funding
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this work.

First published 2001

Printed June 2001 by Solutions Digital Printing.

ii © Australian National Training Authority, 2001

Contents
Getting started........................................................................................................................................... 1

Diagnose basic faults ................................................................................................................................ 4

Activity 1 – Diagnose basic faults ............................................................................................................. 6

Maintain vehicle systems........................................................................................................................... 8

Activity 2 – Vehicle maintenance............................................................................................................... 9

Carry out minor repairs ........................................................................................................................... 12

Activity 3 – Minor repairs ........................................................................................................................ 13

Sign off by Coach and Trainee................................................................................................................. 15

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 Carry Out Maintenance of Vehicles Designed to Carry Special Loads

Getting star ted

Welcome to the Unit of Competence – Carry Out Maintenance of Vehicles
Designed to Carry Special Loads. This unit covers the skills and knowledge
required to maintain, service and carry out minor repairs on vehicles designed to carry
special loads.

The unit of competence consists of four elements and performance criteria as follow:

Element 1

Diagnose vehicle faults and undertake repairs for the safe operation of a vehicle

• Faults in the vehicle and/or ancillary equipment electrical system are identified,
diagnosed and repaired following manufacturer’s specifications and company
procedures
• Faults in the fuel system are identified, diagnosed and repaired following
manufacturer’s specifications and company procedures.

Element 2

Maintain the vehicle systems

• Fluid levels in the vehicle and/or ancillary equipment are checked and adjusted
following manufacturer’s specifications and company procedures
• Air levels in the vehicle and/or ancillary equipment are checked and adjusted
following manufacturer’s specifications and company procedures.

Element 3

Carry out minor repairs to a vehicle

• Vehicle components are removed, repaired or replaced and refitted to the vehicle
using the correct tools and following manufacturer’s instructions and company
procedures
• Tyres are repaired or replaced on vehicle following company procedures and
manufacturer’s instructions
• The need for more complex maintenance procedures is identified and the problem
correctly referred following company procedures.

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Carry Out Maintenance of Vehicles Designed to Carry Special Loads

Element 4

Complete documentation

• Records of routine maintenance and repairs are kept in accordance with company
procedures.

There are three sections to this Workplace Trainee Workbook which cover the four
elements outlined above. These are:

Section 1 – Diagnose basic faults

Section 2 – Maintain vehicle systems

Section 3 – Carry out minor repairs

With the assistance of your Workplace Coach, use the following steps to complete this
Workplace Trainee Workbook and achieve competency in the unit:

Work through the Checklist at the beginning

of the Workplace Trainee Workbook

Complete the sections of the Workbook

that you need to complete

Revisit the Checklist to re-check your

competency

Complete the Sign Off section of the

Workbook when competency has been
achieved

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 Checklist
Together with your coach, work through the following checklist to determine the skills and
knowledge you already have. This will ensure that you don’t have to re-learn them and
that you target only those skills and the knowledge that you need.

Then when you have worked through the required sections of this Workbook, you should
return to this checklist to re-check your competency. When you are able to tick each box
in the checklist you will be ready to proceed to formal assessment for the unit of
competency.

Are you able to:

 Identify, diagnose and repair faults in a food transport vehicle’s electrical and
fuel systems?

 Check and adjust the vehicle’s fluid levels?

 Check and adjust the vehicle’s tyre pressure?

 Remove, repair, replace and refit vehicle components by following workplace

policies and procedures and manufacturer’s instructions?

 Repair or replace tyres on the vehicle by following workplace policies and

procedures and manufacturer’s instructions?

 Identify the need to refer complex maintenance tasks or repairs to other people?

 Keep records of maintenance and repairs in accordance with workplace policies

and procedures?

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Diagnose basic faults

What do I have to do?
Complete ‘Activity 1 – Diagnose Basic Faults’.

To do this you should:

• Discuss with your coach the electrical and fuel systems of workplace vehicles
designed to carry food cargo
• List the vehicle’s major electrical components, necessary testing tools/equipment
and any common faults
• List the vehicle's major fuel system components, necessary testing tools/equipment
and any common faults.

Background information
To complete this section of the Workplace Trainee Workbook you will need to understand
the operation of a food transport vehicle’s:

• Fuel system
• Electrical system.
It might also be helpful to have access to your workplace’s OHS Representative to ensure
that all policies and procedures are safely and effectively followed.

This could help

Electrical components might include:

• Headlights
• Park, tail and number plate lights
• Indicator lights
• Horn
• Windscreen wipers and washers
• Heater and demister
• Stop lights.

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Electrical fault testing equipment might include:

• Ammeter
• Voltmeter
• Ohmmeter
• Test-light.

Fuel system components might include:

• Fuel tank
• Fuel tap
• Fuel lift pump
• Fuel injection pump
• Governor
• Fuel injectors
• Fuel leak off pipe.

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 Acti vity 1 – Diagnose

basic faults
Discuss the electrical systems of workplace vehicles designed to carry food with your
coach and then list in the table below:

• Four major electrical system components

• Necessary testing tools/equipment for each component
• Common faults of each component.

Component Testing tools/equipment Common faults

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Discuss the fuel systems of workplace vehicles designed to carry food with your coach
and then list in the table below:

• Four major fuel system components

• Necessary testing tools/equipment for each component
• Common faults of each component.

Component Testing tools/equipment Common faults

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Maintain vehicle systems

What do I have to do?
Complete ‘Activity 2 – Vehicle Maintenance’.

To do this you should:

• List workplace procedures for checking and adjusting fluid levels in food transport
vehicles
• List workplace procedures for checking and adjusting tyre pressure in food transport
vehicles
• List workplace records that need to be maintained when carrying out routine
maintenance, faults and repairs, and state the purpose of each of these documents
• Using the checklist in the worksheet as a guide, show your coach how you would
change a fuse and replace a tail light lens in a workplace food transport vehicle.

Background information
To complete this section of the Workplace Trainee Workbook you will need to know how
to gain access to relevant workplace information and forms. Ask your coach for
assistance if you require permission to collect this information.

To effectively fill out workplace records you will need to:

• Collect, analyse and organise information

• Write clearly and legibly on all required documents.

This could help

Vehicle maintenance checks include:

• Cooling system
• Radiator
• Tyres
• Oil
• Brake fluid.

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 Acti vity 2 – Vehicle

maintenance
List the requirements for checking and adjusting the following fluid levels:

Cooling system

Radiator

Oil

Brake fluid

List the requirements for checking and adjusting tyre pressure:

Tyres

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Carry Out Maintenance of Vehicles Designed to Carry Special Loads

List workplace records that need to be completed when carrying out routine
maintenance, faults and repairs, and state the purpose of each of these documents

Workplace document Purpose

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 Carry Out Maintenance of Vehicles Designed to Carry Special Loads

Using the following checklist as a guide, show your coach how you would change a fuse
and replace a tail light lens on a food transport vehicle.

When you have carried out each task, your coach will ‘tick off’ the relevant box to indicate
your competence.

Performance required Steps to be completed Tick box

• Prepare the vehicle

• Remove the fuse

Change a fuse •

•
Replace with new fuse

Reconnect the battery


• Observe OHS
procedures.

• Prepare the vehicle

• Remove the lens

Replace a tail light lens
• Replace with new lens 
• Observe OHS
procedures.

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Carry Out Maintenance of Vehicles Designed to Carry Special Loads

Car r y out minor repair s

What do I have to do?
Watch your coach, or an ‘experienced performer’, carrying out minor repairs on food
transport vehicles in your workplace.

Complete ‘Activity 3 – Minor Repairs’.

To do this you should:

• List the minor repairs, such as a tyre repair, which can be carried out on food
transport vehicles in your workplace
• List the tools and equipment that are needed to carry out these minor repairs
• Outline the steps you would follow to refer a complex maintenance/repair task to
appropriate workplace people
• Using the checklist in the activity worksheet as a guide, show your coach how you
would change a tyre on a food transport vehicle.

Background information
To complete this section of the Workplace Trainee Workbook you will need to know how
to:

• Safely and effectively use tools and equipment for vehicle repair and maintenance
• Follow workplace housekeeping policies and procedures
• Minimise waste.

This could help

Tools/equipment needed to carry out minor repairs might include:

• Hammers and mallets

• Pliers
• Screwdrivers
• Spanners
• Shifters
• Grease guns.

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 Acti vity 3 – Minor

repair s
Type of repair Tools and equipment required

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Carry Out Maintenance of Vehicles Designed to Carry Special Loads

In the space below, list the steps you would follow to refer a complex maintenance/repair
task to appropriate workplace people:

________________________________________________________

________________________________________________________

________________________________________________________

________________________________________________________

________________________________________________________

________________________________________________________

Using the following checklist as a guide, show your coach how you would change a wheel
on a workplace food transport vehicle.

When you have carried out each task, your coach will ‘tick off’ the relevant box to indicate
your competence.

Procedure Tick box

Park and secure the vehicle in preparation for changing the tyre. 
Place warning devices in appropriate positions on the road. 
Locate the jack and stand. 
Remove the spare tyre from vehicle. 
Jack the vehicle/axle to appropriate height. 
Release pressure from wedge, if fitted. 
Remove all nuts, studs and wedges (as applicable). 
Remove the wheel and spacer/dish rim. 
Replace the wheel and tighten all nuts. 
Lower and remove the jack. 
Replace all equipment. 

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Observe workplace policies and procedures. 

Record all work carried out in accordance with workplace procedures. 

 Sign of f by Coach and

Tr ainee
The trainee has completed all activities in this Workplace Trainee Workbook and is ready
to proceed to assessment for this unit of competency.

Coach

Date

I have completed all activities in this Workplace Trainee Workbook and believe I am ready
for assessment in this unit of competency.

Trainee

Date

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