TLIB707C - Carry Out Maintenance of Trailers - Learner Guide

TLIB707C Carry
out maintenance
of trailers
Learner Guide
Contents
What this Learner’s Guide is about ........................................ 3
Planning your learning ........................................................... 4
How you will be assessed ...................................................... 7
Section 1............................................................................................. 9
Inspect the suspension and axle, replace inner and outer
bearings ................................................................................. 9
Section 2........................................................................................... 25
Inspect, adjust and make repairs to a trailer air brake system25
Section 3........................................................................................... 45
Carry out repairs to the electrical system of a commercial
vehicle trailer ........................................................................ 45
Additional resources ....................................................................... 53
Assessment tasks ........................................................................... 55
Feedback on activities .................................................................... 67
Training record information ........................................................... 71

Assessment checklist and record sheets ............................. 77
Training record sheet ............. Error! Bookmark not defined.
TLIB707C Carry out maintenance of trailers
Page 2 © Australian National Training Authority 2003

ADELG1036 Customised and developed by Armstrong’s Driver Education P/L July 2008
What this Learner’s Guide is about
This Learner’s Guide is about the skills and knowledge required to
carry out basic servicing and maintenance of a commercial trailer,
including action to implement the trailer manufacturer's specifications
for routine checks and maintenance and to ensure that all specified
safety requirements are met and that the trailer 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 TLIB707C Carry out
maintenance of trailers covered in this Learner’s Guide are listed
below.
Identify faults and perform routine maintenance
Carry out repairs on trailers
Complete documentation
This unit of competency is from the Transport and Logistics
Training Package (TLI07).
© Australian National Training Authority 2003 Page 3

Customised and developed by Armstrong’s Driver Education P/L July 2008 ADELG1036
Planning your learning
It is important to plan your learning before you start because you may
already have some of the knowledge and skills that are covered in this
Learner’s Guide. This might be because:
• you have been working in the industry for some time,
and/or
• you have already completed training in this area.
Together with your supervisor or trainer use the checklists on the
following pages to help you plan your study program. Your answers to
the questions in the checklist will help you work out which sections of
this Learner’s Guide you need to complete.
This Learner’s Guide is written with the idea that learning is made
more relevant when you, the learner, are actually working in the
industry. This means that you will have people within the enterprise
who can show you things, discuss how things are done and answer any
questions you have. Also you can practise what you learn and see how
what you learn is applied in the enterprise.
If you are working through this Learner’s Guide and have not yet found
a job in the industry, you will need to talk to your trainer about doing
work experience or working and learning in some sort of simulated
workplace.

Section 1: Inspect the suspension and axles,

replace inner and outer bearings
Are you able to: Yes No

1. identify various commercial vehicle trailer
suspension types?
2. perform a service inspection on a
commercial vehicle trailer suspension?
3. perform a basic service inspection to a
commercial vehicle trailer axle?
4. replace inner and outer wheel bearings on
a commercial vehicle trailer?
Section 2: Inspect, adjust and make repairs to a

trailer air brake system

1. outline the fundamentals of compressed
air brakes?
2. correctly identify nominated trailer brake
components?
3. correctly diagnose a common air brake
fault on a commercial vehicle trailer?
4. carry out a brake adjustment to a
commercial vehicle trailer?
5. repair an air leak in a trailer air brake
system?

Section 3: Carry out repairs to the electrical

system of a commercial vehicle
trailer

1. trace a selected wiring circuit on a
commercial vehicle trailer and check for
continuity?
2. repair a damaged section of wiring on a
3. replace the bulb on a commercial vehicle
trailer indicator lamp, clearance lamp and a
number plate light?
4. re-‐wire a male electrical plug on a

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:

• undertake a check of trailer suspension
• change a wheel on trailer
• replace a faulty globe on trailer
• replace a lens on trailer.


Section 1
Inspect the suspension and axle,

replace inner and outer bearings

Section outline
Areas covered in this section
Identify various commercial vehicle trailer suspension types
Perform a service inspection on a commercial vehicle trailer

suspension
Perform a basic service inspection to a commercial vehicle trailer axle
Replace inner and outer wheel bearings on a commercial vehicle trailer

Trailer suspension
There are various types of trailer suspension. Some of these are:
• tapered single leaf spring
• tapered triple single leaf spring
• overslung and underslung leaf springs
• two-‐stage multileaf spring
• lastosphere spring used as a booster spring
• rubber load cushion suspension
• rubber shear spring suspension stabilaire rear axle air
suspension.
(a) Tapered single-‐leaf spring (b) Tapered triple single-‐leaf spring.

Schematic view of a two-‐stage multileaf spring in the unloaded stage

Lastosphere spring used as a booster spring
Sectional view of a rubber load cushion suspension

Rubber shear spring suspension

Activity 1: What type of suspension does your trailer have?
What type of suspension is your trailer equipped with?
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Activity 2: Carry out a trailer suspension inspection on your

trailer
Carry out a trailer suspension inspection on your trailer. Only

complete the type of suspension that applies to your vehicle. Ask
your trainer for feedback on your performance.
Is the equipment in good condition? Yes No

Leaf spring suspension check the:
• leaf springs:
− broken  
− misaligned  
• location bolts:
− broken misaligned  
• U-bolts:
− tight  
− not broken or rusted  
• suspension bushes:
− worn  
− damaged  
• spring hangers:
− check their security.  
Is the equipment in good condition? Yes No
Rubber suspension check the:

• rubber cushion:
− security  
− condition  
• drive pin bushing:
− security  
− condition  
• U-bolts:
− tight not worn  
− not broken or rusted.  

Air suspension check the:

• arm pivot nuts:
• air spring nuts (top):
• air spring nuts (bottom):
• shock absorber nuts:
− air springs condition  
• air spring and suspension pipework:
− not leaking  
− nor creased or damaged  
− U-bolts
− not broken or rusted.  
Ask your trainer for feedback on your inspection.

Remove and replace hub oil seal on your trailer

axle
Hub oil seal

1. Removal:
• cage the spring brake adjacent to the hub to be removed and
apply the parking brake
• using a suitable jack under the axle, raise the trailer until the
wheels are clear of the ground and support the axle on safety
stands
• using correct tool remove the hub cap and O-‐ring and discard
the O-‐ring (or remove hub cap bolts and nuts)
• position a wheel trolley jack under the wheels and support the
weight, then straighten the lock tabs on the lock washer and
remove the lock nut using the correct tool (or remove split pin
in axle nut)
• remove the lock washer, then using the correct tool remove
the adjusting nut
• remove the outer wheel bearing, then remove the wheel hub
and brake drum from the axle shaft
• remove the inner wheel bearing from the axle shaft then, using
a hammer, tap the oil seal from the axle shaft; discard the oil
seal
• using a suitable drift (tool), remove the inner and outer
wheel bearing cups (only remove cups if bearings are
to be replaced).
2. Installation (always replace bearing cups as a pair).
• thoroughly clean the hub assembly and the axle shaft, then
using a suitable drift, install the inner and outer bearing cups
into the hub.
• lubricate the outer surface of the oil seal and position the seal
on the axle shaft, ensuring that the side marked Oil Side faces
away from the trailer; on some axles bearings must be located
into hubs before seal is replaced.

Axle assembly - exploded view
Axle assembly -‐ exploded view
Oil seal installation
• Using the fabricated seal installer, seat the seal against the axle
flange.
• NOTE: The wheel bearings are fully floating on the axle shaft.
• Install the inner wheel bearing on the axle shaft (or into the hub
then the seal on some types), then using a wheel trolley jack,
position the brake drum, hub and wheels on the axle shaft.
• Install the outer wheel bearing and the adjusting nut. While
rotating the wheels, tighten the nut using the correct tool to seat
the bearings and the oil seal in the hub.
• Back off the adjusting nut counter-‐clockwise approximately 60

degrees until the wheels rotate freely. Check workshop manual for
manufacturer’s specifications.
• Install the lock washer and lock nut, then bend the lock tabs to
secure the adjusting nut and the lock nut.
• Install a new O-‐ring on the hub cap, lubricate the O-‐ring and the
hub cap threads then install the cap and tighten securely using the
correct tool.
• Raise the axle and remove the safety stands.
• Fill the hub cap and hub cavity with a suitable oil to the level
indicated on the cap.

Hub cap oil level indicator
• Release the parking brake and uncage the spring brake.
Remove, check, repack and replace and adjust

wheel bearing on trailer
Trailer wheel bearing adjustment
Wheel bearings must be correctly adjusted and properly lubricated at
regular intervals to achieve maximum bearing life, prevent damage to
hubs, axels and probably the trailer. Changing the wheel bearing
lubricant is recommended every 50,000 km, depending on vehicle
speed, loads, and general operating conditions. Proceed as follows
when changing lubricant and inspecting bearings:
1. Remove wheel assembly and bearing cones from axle
spindle. Clean all old lubricant from hub, bearings, and hub
cap with a good grade commercial cleaner and stiff brush,
NOT STEEL.
DO NOT use air hose in cleaning operation. Avoid spinning
cone while cleaning.
2. Wipe the cleaned parts dry with clean absorbent cloth or
paper. Clean and dry hands and all tools used in the service
operation. Lubricant will not adhere to a surface which is
wet with solvent, and the solvent may dilute the lubricant.
CLEANLINESS IS MOST IMPORTANT.
3. Inspect seals, seal wiping surfaces, bearing cups, and
bearing cones for wear or damage. Handle all parts
carefully during cleaning, inspection, and installation to
prevent damage to bearing cage, rollers and cone.
4. Check bearing cones with cups for correct fit and number.
The bearing (cup and cone) MUST MATE.
CAUTION: Always use correct cup with mating cone, never
mix parts.
5. Grease lubricated bearings -‐ pack the bearing with a
pressure packer if possible, using an approved lubricant of
medium consistency. If a pressure packer is not available,
pack bearings by hand by forcing the grease into the
cavities between the rollers and cage from the larger end
of the cone. Coat inside the hub cap with a light coat of
grease, to prevent moisture accumulation.

6. Be sure air tank is drained and release brake shoes so there
will be no possibility of brake shoe drag interfering with
bearing adjustment. Assemble and adjust wheel bearings
as follows:
a. If grease is used, fill the cavity of the hub between the bearing
cups to a level of the bearing cup diameter (as per
manufacturer’s specifications).
b. Determine inner cup number and install matching cone in
wheel, then check to see that the cone is properly seated in
the cup.
c. Install oil or grease seal as recommended by manufacturer.
d. Install wheel on axle, being careful not to damage the bearing
cups, cones or seal.
e. Determine outer cup number and install matching cone, then
check to see that the cone is properly seated in the cup.
f. DOUBLE NUT AXLE -‐ Install wheel bearing adjusting nut. Screw
adjusting nut against the bearing as the wheel is being
revolved in both directions, to expel excess lubricant and
insure proper seating of bearing rollers.
g. It is recommended that a torque wrench be used assembling
of the adjusting nut. The adjusting nut should be tightened to
torque recommended by trailer manufacturer. If torque
wrench is not available, tighten adjusting nut with a bar 3.0 to
4.0 cm in length pushing down with full arm strength (not
body weight) while rotating the wheel in both directions.
h. Back off adjusting nut 2 to 21/2 holes on the lock ring or 1/4 of a
turn.
i. Install wheel bearing lock washer and jam nut and tighten to
torque recommended by trailer manufacturer. If a torque
wrench is not available, tighten jam nut with a 3.0 to 4.0 cm
bar with a full body weight. The wheel should rotate easily but
not have excessive play.
j. Check final bearing adjustment with a dial indicator.
Adjustment should be made to the torque recommended by
your trailer manufacturer’s recommendation. If a dial indicator
is not available, check bearing adjustment for play by using pry
bar under hub or tyres.
k. Should bearings be improperly adjusted, repeat sections F to I.
l. Install hub cap with proper gasket. Torque to the
manufacturer’s recommendation for the cap screws on the
hub cap.

m. After each run, visually inspect wheels and brake drums for
damage or leaks. Keep close check on all moving parts to
obtain maximum life.
Record all routine maintenance and repairs
Routine maintenance and repairs must be recorded in accordance with
company procedures. Major repair items should be identified and your
trainer advised of these.

Activity 3: Demonstrate to your trainer axle fault diagnosis
Demonstrate to your trainer your knowledge in fault diagnosis on

your trailer. Use the faults indicated in the example below, fill in the
possible causes.
Faults and their probable causes
Fault Cause
Hub running hot
Premature bearing failure
Damaged wheel studs/bolts
Broken axle beam

Fault Cause
Excessive tyre wear
Brakes binding
Inefficient brakes
There is feedback on this activity at the back of this Learner’s

Guide.


Section 2
Inspect, adjust and make repairs

to a trailer air brake system

Section outline
Outline the fundamentals of compressed air brakes
Correctly identify nominated trailer air brake components
Correctly diagnose a common air brake fault on a commercial vehicle

trailer
Carry out a brake adjustment to a commercial vehicle trailer
Repair an air leak in a trailer brake system

The fundamentals of compressed air brakes
Components of compressed air brakes:
Compressor:
• furnishes the compressed air for braking operation by taking free
air or atmosphere and compressing it.
Reservoir:
• the compressed air passes from the compressor into the reservoir
where it (and its energy) are stored until needed.
Brake valve:
• the compressed air is held in the reservoir until released by the
driver operating air control valves.
Service brake system:
• when the brake valve is operated by the driver, air flows to the
chambers where its energy is transformed into the mechanical
force and motion necessary to apply the brakes.
Trailer system

The fundamentals of compressed air brakes

Activity 4: Locate graph showing differences in braking

forces
Obtain from your manufacturer’s manual or a brake specialist a

graph or table showing the differences in braking force
requirements for vehicles and loads. Paste this below for your
reference.

Air brake maintenance
The air brake system is the most important safety system on a vehicle.
Yet, the maintenance of the system is a fairly simple job, capable of
being performed by any mechanic with the use of ordinary shop tools.
The maintenance of the system can be broken down into two major
areas:
• pneumatic factors
• mechanical factors.

1. Pneumatic Factors
An ideal braking system can be defined as one in which the
braking pressure reaches each actuator at the same time
and at the same pressure level. One of the factors that
affects this performance is the selection of tubing and
hose sizes. Air application and release performance is
partially dependent upon the size and volume of
chambers, vehicle weights and locations of the valves and
chambers, or distance the air must travel. Performance is
engineered into the vehicle by the manufacturer; the role
of the vehicle owner and/or mechanic is to preserve that
pneumatic performance.
2. Tubing
When replacing tubing or hose, always replace with the
same size. These sizes have been determined by the
vehicle manufacturer to obtain desired performance.
Copper tubing should not be used in the hydraulic system.
Be carefully not to kink or crack the tubing when bending
to fit the frame or rear axle forms. Make sure tubing and
hose are properly supported.
Repairing a damaged brake tube
Line flaring sequence

1. Cut off and straighten the required length of one tube (a
tubing cutter tool will simplify making a clean and square
cut).
2. Square off the ends of the line with a file, and chamfer the
end of the line to be flared.
3. Select the split die for the line to be used and insert the die
into the tapered hole in the body.

4. Push the tube through the die until the line is even with
the face of the die. Lock the line in this position by
tightening the wing nut securely.
5. The punches are marked Op.1 and Op.2. Slide the first
operation punch into the hole in the centre of the body
and tighten the screw securely to form the single flare.
6. Release the screw and replace the first operation punch
with the second punch and tighten the screw to form the
double flare.
7. Release the screw, wing nut, punch and dies.
8. Remove the line and inspect the flare for cracks or poor
flare form. If the flare is not correct, cut it off and repeat
the process.
9. The finished flare must be square with the line, free of
cracks and have a smooth mating surface to ensure a leak
proof connection.
10. Repeat maintenance and repairs in accordance with
company procedures.

Activity 5: Demonstrate for your trainer the repair and

replacement of a section of damaged brake line
Using a scrap piece of fuel line (or repair a leaking fuel line on your
vehicle), make a line flared joint. Ask your trainer for feedback on
your effort.

Brake hose
Replace a flexible brake hose if it shows signs of softening, cracking or
other damage.
When installing a new brake hose, position the hose to avoid contact
with other vehicle parts.

Activity 6: Replace a brake hose on your vehicle

Demonstrate for your trainer how you would replace a brake hose
on your vehicle. Ask your trainer for feedback on your performance.

Brake wheel cylinder
Disassembly
1. With the wheel cylinder removed, remove the rubber
boots from the ends of the brake cylinder. Remove the
pistons, cups, and piston return spring and piston
expander assembly from the cylinder.
2. Remove the bleeder screw from the cylinder.
Assembly
1. Coat all brake cylinder parts with clean extra heavy duty brake fluid
as recommended by the manufacturer’s manual.
2. Install the bleeder screw in the brake cylinder.
3. Place the piston return spring and piston expander assembly, cups,
and pistons in the cylinder bore, and install a boot and link over
each end of the cylinder. Clamp the brake cylinder pistons against
the ends of the cylinder. When using a brake cylinder repair kit
follow the instructions in the kit and use all of the parts provided.
Replace brake shoes and adjusting mechanism
1. Raise the vehicle until the tyres clear the floor and install safety
stands. Remove the wheel and tire assembly. Remove the drum or
the hub and drum assembly. Mark the hub and drum to aid
assembly in the same position.
2. Expel all vacuum in the system before disconnecting the hydraulic
lines. Expel vacuum in the system by pushing down on brake pedal
when engine is off.
3. Remove the shoe retracting springs and hold-‐down C-‐clips. Lift off
the shoes.
4. To remove an automatic adjuster from the shoe, unhook the

wedge actuating coil spring from the wedge. Unhook the lever
actuating spring from the shoe web. Work the spring coil off the
lever pivot pin and slide the spring `U’ hook off the contact plug-‐
lever pin. Pull the adjuster lever from the opposite side of the shoe
web, contact the plug through the shoe table and lift off the
wedge washer, wedge and the wedge guide.
Installation

1. To install the adjuster assembly, position the wedge guide with its
pin in the hole provided in the brake shoe. Place the wedge guide
on the side of the brake shoe farthest away from the carrier plate.
Position the wedge on the shoe web with its serrated edge resting
against the serrations on the wedge guide so the slot is aligned
with the lever pivot pin hole.
2. Insert the contact plug from the drum side of the shoe, guiding its
shank through the hole in the shoe table over the wedge and
wedge guide.
3. Insert the adjuster lever pins through the shoe web from the
opposite side of the shoe, guiding the actuating (centre) pin into
the mating hole of the contact plug shank. Place the wedge washer
over the shoulder of the pivot pin.
4. Slide the `U’ hook of the adjuster spring on the pin over the contact
plug shank. Attach the end of the wedge actuating spring to this
hook, then install the coil of the adjuster torsion spring over the
pivot pin and pull the spring hook over the edge of the wedge.
5. Connect the other end of the wedge spring to the hook of the
wedge.
6. Fully retract the wedge against the lever pivot pin by pressing the
contact plug to permit the contact. If the plug sticks out more than
0.005. inch above the lining, clamp the brake shoe in a vice so the
vice jaws bear against the adjuster lever and dress down the plug.
This can be done with a file, taking care not to file a flat spot on the
lining.
7. Place the shoe assemblies (correct shoes, use the manufacturer’s

specification)on the carrier plate with the shoe hold-‐down studs
through the oval shaped hole in the shoe webs. Place the shoe
assemblies on the wheel cylinders.
8. Install the flat washers and bowed washers, and crimp the C-‐
washers on the hold-‐down studs to secure the shoes.
9. Install the brake shoe retracting springs with the long end hooked
at the anchor end of the shoe. Be sure the shoe webs are engaged
in the wheel cylinder piston insert slots.
10. Install the hub and drum assembly.
11. Adjust and bleed the brakes as described below.
12. Record and report maintenance and repairs in accordance with
company procedures.

Hydraulic system bleeding
When any part of the hydraulic system has been disconnected for
repair or replacement, air may get into the lines and cause spongy
pedal action. This requires the bleeding of the hydraulic system after it
has been properly connected to be sure all air is expelled from the
brake cylinders and lines. The hydraulic system can be bled manually or
with pressure bleeding equipment.
Bleed one brake cylinder at a time. Start bleeding on the right rear
brake, then the left rear. After completing, proceed to bleed the right
front brake, then the left front. Keep the master cylinder reservoir
filled with the specified Heavy Duty Brake Fluid during the bleeding
operation. Never use brake fluid which has been drained from the
hydraulic system.
If the hydraulic system is equipped with a frame mounted vacuum

booster, bleed the hydraulic section of the booster before bleeding
the rest of the system. On vehicles with a frame-‐mounted booster and
split hydraulic brake system, bleed the two booster slave cylinders
first, then again after bleeding all the wheel cylinders. Bleed the
system with the engine off and with no vacuum in the system. If the
brake pedal is still spongy after the first bleeding, repeat the bleeding
procedure.
Bleed the hydraulic section of brake line between the master cylinder
and the vacuum booster, by attaching the drain tube to the bleeder
screw at the end plate of the booster (or the bleeder screw nearest
the power chamber). Repeat this procedure at the other bleeder
screw, (if equipped).
Before any attempt is made to bleed the split hydraulic brake system,
remove the brake light warning switch from the pressure differential
valve. Failure to remove the switch from the valve could result in
possible damage to the switch assembly.
Manual adjustment -‐ with drums installed
Adjust the single anchor brake by turning an adjusting screw located
between the lower ends of the shoes.
1. Raise the trailer until the tyres clear the floor.
2. Remove the cover from the adjusting hole at the bottom of the
brake backing plate, and turn the adjusting screw inside the hole to
expand the brake shoes until they drag against the brake drum.

3. When the shoes are against the drum, loosen the adjusting screw
an additional 1.0 to 1.2 notches so that the drum rotates freely
without drag. If the drum does not rotate freely, remove the wheel
and drum, and blow out any dust and dirt from the linings. Using
sand paper, remove any rust from the points where the shoes
touch the backing plate. Apply a light coating of Multi-‐Purpose
Lubricant. Do not get the lubricant on the linings.
4. Install the wheel and drum, and adjust the shoes. Install the
adjusting hole cover on the brake backing plate.
5. Check and adjust the other three brake assemblies.
6. Apply the brakes. If the pedal travels more than halfway to the
floor, there is too much clearance between the brake shoes and
the drums. Repeat Step 2 and 3 above.
7. When all brake shoes, have been properly adjusted, lower the
vehicle and road test to check brake operation. Perform the road
test only when the brakes will apply and the vehicle can be safely
stopped.

Activity 7: Manually adjust your vehicle brakes

Demonstrate to your trainer the manual adjustment of your trailer
brakes.

Brake adjustment
Probably the most important factor in obtaining maximum mechanical

output of the chamber is proper brake adjustment. All chamber
strokes should be adjusted to approximately the same stroke, and the
adjustment should be made so that the chamber stroke is as short as
possible without the brakes dragging. Improperly adjusted brakes
waste air and leverage, and contribute to poor brake performance.
In many cases, complaints of poor or insufficient brakes can be taken
care of by proper brake adjustment.
The importance of reservoir draining
The contaminants that collect in air brake reservoirs consist of water
condensed from the air and a small amount of oil from the
compressor. This water and oil normally pass into the reservoir in the
form of vapour because of the heat generated during compression.
There is probably no more simple yet more important maintenance
than reservoir draining. All reservoirs not equipped with automatic
draining devices or moisture removal devices should be drained daily.
All automatic drain valves and moisture removing devices should be
checked periodically for proper operation.
As the complexity of the air brake system has increased, so has the
need for clean air. Many of the later design valves contain small
orifices and passages and, thus, are more susceptible to contaminants.
In addition, the prevention of freeze-‐ups in the system is equally
important. The development of the Air Drier has been an important
development in providing clean, dry air, and its use is highly
recommended. Alcohol evaporators also serve the system, helping to
prevent freeze-‐ups.
Caution notes for maintaining air brake systems
When working on or around air brake systems and components, the
following precautions should be observed.
1. Always block vehicle wheels. Stop engine when working
under a vehicle. Depleting vehicle air system pressure may
cause vehicle to roll. Keep hands away from chamber
push rods and slack adjusters; they may automatically
apply as system pressure drops.
2. Never connect or disconnect a hose or line containing air
pressure. It may whip as air escapes. Never remove a

component or pipe plug unless you are certain all systems
pressure has been depleted.
3. Never exceed recommended air pressure and always wear
safety glasses when working with air pressure. Never look
into air jets or direct them at anyone.
4. Never attempt to disassemble a component until you have
read and understand recommended procedures. Some
components contain powerful springs. Use only proper
tools and observe all precautions pertaining to use of
those tools.
5. Use only genuine replacement parts and components:
• Only components, devices mounting and attaching hardware
specifically designed for use in air brake systems should be
used.
• Replacement hardware, tubing, hose, fittings, etc. should be of
equivalent size, type length, and strength as the original
equipment.
• Make certain that when replacing tubing or hose, all supports,
clamps or suspending devices that were originally installed by
the vehicle manufacturer are reinstalled.
6. Devices with stripped threads or damaged parts should be
replaced. Repairs requiring machining should not be
attempted.
Lubrication recommendations
The use of proper lubricants in air components is extremely important.
Lubricants other than those recommended below may not be
compatible with internal parts and, therefore, are not recommended.

Activity 8: What is the correct lubrication?

From your manufacturer’s manual complete the table below. Fill in
the recommended lubricants for the named devices.
Devices Recommended lubricant
Metal to metal parts such as

treadle rollers, pins, and linkage
DD-3., SD-3. slack adjuster
Compressor unloader
Standard slack adjuster
Automatic slack adjuster
All air brake control devices with

rubber o-rings
Rotochamber and rotowedge

diaphragms
DS-1. fan clutch (with grease

provision)
Speak to your trainer about your responses for this activity.

Maintenance intervals
Because no two vehicles operate under identical conditions, maintenance

intervals will vary. Experience is a valuable guide in determining the best
maintenance interval for your trailer operation.
Therefore, the recommended maintenance intervals shown in your

manufacturer’s manual should be considered as the maximum allowable
interval. Vehicles operating under severe or adverse conditions may
require more frequent service.

Activity 9: What is your manufacturer’s recommendation for

brake servicing?
What is the recommended brake maintenance recommended by

your manufacturer? Use the manufacturer’s manual to locate this
information.
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Ask your trainer if this is a sufficient maintenance schedule for your

trailer, taking into consideration the type of operation you perform.
Write in your trainer’s comments below.
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Section 3
Carry out repairs to the electrical

system of a commercial vehicle
trailer

Section outline
Trace a selected wire circuit on a commercial trailer
Repair a damaged section of wiring on a commercial vehicle trailer
Replace the bulb on a commercial vehicle trailer indicator lamp, clearance

lamp and a number plate light
Rewire a male electrical trailer plug on a commercial vehicle trailer

Removing, rewiring and replacing electrical

parts
Any attempt to drive your vehicle when a body electrical part has been
removed from its circuit may be dangerous and must be prevented by
correctly preparing your vehicle.
To prepare your vehicle for the removal and replacement of body

electrical parts:
• park your vehicle on a flat level surface
• select neutral and chock the wheels
• apply the park brake
• disconnect the battery.

Activity 10: Rewire a male trailer plug on your vehicle

Re-wire a male electric trailer plug on your vehicle trailer.
Did the learner Yes No
1. Use the correct hand tools to remove cover

from male plug to expose wiring?
2. Use a wiring diagram to show the standard

wiring code, or did they draw a diagram,
marking in the wiring colours and contact
references?
3. Check the wiring ends before commencing

the re-wiring process, to make sure the wires
were clean and undamaged?
4. Rewire the male trailer plug making sure the

wires matched the following?
• left indicator:
− yellow wire in No. 1.
• auxiliary:
− blue wire in No. 2.
• earth:
− white wire in No. 3.
• right indicator:
− green wire in No. 4.
• auxiliary:
− black wire in No. 5.
• stop:
− red wire in No. 6
• tail, No. Plate and clearance:
− brown wire in No. 7.
5. Replace the wiring cover, using the correct

hand tool?
6. Check all the lights to make sure the re-

wiring task was carried out correctly?
Ask your trainer to give you feedback on your performance.

Activity 11: Replace a blown indicator globe on your trailer
Demonstrate for your trainer or mechanic the removal and

replacement of your trailer indicator globe, a clearance lamp globe
and your number plate globe.

Activity 12: Test the continuity of a low tension lead
Test for a short circuit or a break in a low tension lead with a series
test-light.
1. Prepare the series test-light, connect input

lead to the vehicle’s battery?
2. Disconnect the input and output leads from

the part:
• use a suitable tool to disconnect the
screw type
• pull on the terminal cover to disconnect
the push-on type?
3. Connect the red test-clip to the input terminal

and the black test-clip to the body (earth) on
the part being tested?
4. Turn on the test-light switch?
5. Observe the test-light?
(The light will glow when a short circuit

exists.)
6. Turn off the test-light switch?
7. Disconnect the test-light clips from the part?
8. Disconnect the test-light input lead from the

vehicle’s battery?
9. Reconnect the input and output leads to the

part and make sure they are secure?
1.0. Check the operation of the circuit?

Activity 13: Replace a faulty low tension lead on your trailer
Replace a faulty electrical low tension lead. Ask your trainer to

check your work.
1. Select a roll of new LT lead with the same

amp rating or a higher amp rating than the
original?
2. Select the same colour wire for identification

purposes:
• select suitable terminals and terminal
covers:
− use the same type as those which
were cut from the old lead?
3. Measure the length of the original lead and

cut the same length from the roll?
4. Correctly fit the terminal covers to the lead?
5. Lay the lead along the wiring harness?
6. Release the wiring harness tabs or spring

clips?
7. Use insulation tape to secure the lead to the

wiring harness in several places?
8. Reclamp the wiring harness to the body?
9. Connect both ends of the lead to their

respective parts?
10. Connect the battery and the operation of the

circuit?

Replace tail light lens
To remove lens from external light:

• determine the retaining method; it may be:
− two or more screws through the lens
− two or more screws through a retainer or a trim
• using a suitable screwdriver, remove the screws while
holding the lens
• remove the retainer (where applicable)
• grip the lens firmly and ease it away from the light body
• remove and discard the seal
• obtain the replacement lens and seal from stores:
− make sure it is a genuine replacement part
• install a new seal to the body of the lens
• position the lens on the light body
• secure the retaining device:
− insert and tighten the retaining screws while the lens is held
firmly against the light body
• check that tail lights are working
• record and report maintenance and repairs in accordance with
company procedures.

Additional
resources

Paper based:
• relevant learners handouts, guidelines and reference
materials, such, as:
− The Australian Truck Drivers Manual
− Guidelines for the safe carriage of loads on road vehicles, ‘Load
Restraint Guide’
− state/territory regulation authority material e.g. RTA (NSW)
Heavy Vehicle Drivers’ Handbook. Vic Roads’ The Victorian
Bus and Truck Drivers’ Handbook. Other material may be
obtained from various state/territory authorities
− relevant government acts and legislation, covering heavy vehicle
road law and operation
− relevant manufacturer’s manuals
• a range of trucks specific to training requirements
• spare parts required for relevant tasks
• a range of hand tools and equipment
• cleaning materials
• written assessment tasks, where required
• real or simulated road transport environment.

Assessment
tasks

These assessment tasks relate to the Unit of Competency

TDT B7 97B Carry out maintenance of trailers
Elements of competency
Identify faults and perform routine maintenance
Carry out repairs on trailers
Complete documentation
Assessment 1: Check trailer suspension
Sub-Tasks Steps Assessment Initials of

Did the learner: (Comp, NYC) Assessor
1. Check leaf spring Check for:
suspension • broken or misaligned
leaf springs?
• broken or misaligned
locating bolts and
centre bolt?
• tightness of U-bolt
(visually)?
• worn or damaged
suspension bushes?
• security and condition
of spring hangers?
2. Check air bag Check for:
suspension • security and condition
of rubber cushion?
of drive pin bushing?
• visible damage to and
security of load
levelling devices?
of air bag mountings?


3. Report faults • take corrective action
on those matters which
are considered the
driver’s responsibility?
• report all other faults to
the appropriate
company personnel so
that corrective action
may be taken?
4. Observe OHS • observe and
procedures implement all
Occupational Health
and Safety practices
while conducting the
trailer suspension
check?

Assessment 2: Change a wheel

1. Park and secure • park on a level flat
the vehicle hard surface to allow
jack to be used
safely?
• switch off the ignition?
• switch the hazard
warning light on?
• place reflective
triangles/portable
lamps in appropriate
positions?
• place chocks in front
of and behind the
wheels, other than the
wheel to be jacked?
2. Locate jack and • check jack and stand
stand are in good condition?
• check jack and stand
have adequate load
capacity?
3. Remove spare tyre • remove spare wheel
from carrier from carrier?
• place spare wheel
beside the flat tyre?
4. Jack the • locate jack points?
vehicle/axle to • place ‘base plate’
appropriate height under jack?
• place jack and stand
under axle housing,
as close to the flat
tyre as possible?
• jack the vehicle until
saddle engages the
jacking point, and the
jack ‘takes the weight’
of the vehicle?


• loosen wheel nuts
with a wheel brace,
without fully
removing?
• jack the vehicle until
the wheel is free from
road surface?
• place safety stands (if
appropriate), below
the axle and as close
to the jack as
possible?
5. Release pressure • safely release
from cleats, if fitted pressure from wedge
by tapping with wheel
brace?
6. Remove all nuts, • loosen nuts, studs
studs and cleats (as and cleats with wheel
applicable) brace, and remove?
• place nuts, studs and
cleats onto flat
surface or an
appropriate place?
7. Remove outer • place wheel brace
wheel and handle under bottom
spacer/dish rim of tyre, and take
weight off tyre?
• use a short sharp
upward movement
with wheel brace
handle?
• remove wheel with
their back to the
wheel, and by placing
both hands under top
of rim of wheel?


• ensure the wheel does
not damage studs (as
applicable), as the
wheel is removed?
• lean the wheel against
the vehicle?
• remove and place
spacer (as applicable)
beside the removed
wheel?
8. Remove inner • place wheel brace
wheel handle under bottom of
tyre, and take weight
off tyre?
• use a short sharp
upward movement with
wheel brace handle?
• pull tyre with other
hand?
• slide rim off hub?
9. Replace inner • check spare tyre and
wheel clean dirt from its rim?
• place the rim into
position, lined-up with
the spider, hub or
retaining studs, and
ensure the valve faces
outwards?
• use wheel brace
handle to lift tyre, then
push wheel into
position, ensuring
valve is centred
between two studs?
• inspect, clean then refit
the spacer/dish rim (as
applicable)?


10. Replace outer • ensure that the valves
wheel and tighten are placed so access
wheel nuts to both is easy?
• replace individual
cleats, retaining studs
and nuts?
• tighten all nuts in
sequence, (refer to
diagrams overleaf)?
• rotate the wheel, and
check ‘run-out’ on the
rim?
• confirm ‘run-out’ is
aligned correctly?
• re-tighten all nuts in
sequence?
11. Lower and • smoothly lower and
remove jack remove the jack
safely?
• securely tighten all
wheel nuts in
sequence?
12. Replace • place flat tyre into
equipment carrier and re-secure?
• replace tools, jack and
stand?
• remove chocks,
warning signs/hazard
lights?
practices implement
occupational health
and safety practices,
during all sub-tasks in
the wheel changing
process?

Assessment 3: Replace a faulty globe

1. Prepare the • park the vehicle on a
vehicle flat level surface, if
possible?
• engage ‘Neutral’, if
maxi brakes are fitted,
or a gear contrary to
the prevailing slope?
• confirm the park brake
was applied and
holding?
• isolate the circuit in
accordance with
company policy and
vehicle specification?
2. Remove the globe • ensure the appropriate
circuit is off?
• correctly gain access
to globe depending on
whether rear of light
can be exposed?
• correctly identify the
blown globe and
withdraw it from the
holder?
3. Replace the globe • check that the
replacement globe is
the correct type?
• ensure that the holder
contacts are clean, or
clean if required?
• install the globe
without use of undue
force?
• check the globe’s
operation before
replacing lens?


• confirm that the lens
cover was correctly
sealed?
procedures implement
occupational health
during all sub-tasks
while replacing the
globe?

Assessment 4: Replace a lens

1. Prepare the • park the vehicle on a
vehicle flat level surface, if
possible?
• engage ‘Neutral’, if
maxi brakes are fitted,
or a gear contrary to
the prevailing slope?
• confirm the park brake
was applied and
holding?
• isolate the circuit in
accordance with
company policy and
vehicle specifications?
2. Remove the lens • determine the retaining
method?
• use the correct screw
driver?
• ease lens away from
light body without
leverage?
• remove and discard
the seal?
3. Replace lens • use an appropriate,
company approved
replacement part?
• install a new seal?
• correctly position the
lens on the light body?
• secure the retainer or
trim firmly?
• check that seal and
lens are installed
properly?
• check that light is
working?


procedures implement
occupational health
during all sub-tasks
while replacing the
lens?


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: Demonstrate to your trainer axle fault diagnosis
Faults and their probable causes
Fault Cause
Hub running hot Bearings incorrectly adjusted.
Under or over greasing, or
unsuitable grease.
Premature bearing failure Bearings installed wrongly (too
tight or too free).
Insufficient or unsuitable grease.
Dirt or foreign bodies in hub.
Wrong offset wheels fitted.
Excessive shock loading (kerb
mounting or hitting pot holes at
speed).
Overloading.
Damaged wheel studs/bolts Insufficient care taken in the fitting
of wheel studs or bolts.
Wheel stud locknut inside drum
not properly tightened and locked,
consequently stud will eventually
work loose in service.
Wheel nut not tightened to
recommended torque.
Broken axle beam. Overloads.
Inferior welding.
Welding across high stress zones.
Spring seat centres below
recommended minimum

Fault Cause
Excessive tyre wear Incorrect tyre pressures.
Loose ‘U’ Bolt nuts.
Axle out of alignment.
Tyres unmatched.
Spring seats off axle top dead
centre (toe-in or tow-out).
Bent axle.
play in bearings (excessive end-
float).
Brakes binding Faulty return spring.
Delay in brake release valve or
brake chamber.
Inefficient brakes Worn linings
Air pressure loss.
Slack adjuster needs taking up.
Slack adjuster collar stop pin
sheared or loose.
Failed hub seal permits grease to
leak onto brake linings.
Worn cam shafts.


Training record
information
for
TDT B7 97B Carry out maintenance of trailers

Personal details
Name ...........................................................................................................
Telephone number .......................................................................................
RTO details
Name of RTO ..............................................................................................
Name of RTO trainer/assessor ....................................................................
Employer details
Name ...........................................................................................................
Address .......................................................................................................
......................................................................................................................
Workplace supervisor/trainer’s name .........................................................
Workplace supervisor/trainer’s work telephone number .............................
Complete this section if you have two different employers or

you change employers.
Name ...........................................................................................................
Address .......................................................................................................
......................................................................................................................
Workplace supervisor/trainer’s name .........................................................
Workplace supervisor/trainer’s work telephone number ............................

Introduction
This training record information is part of the Learner’s Guide for this unit
of the Transport and Distribution Training Package.
The training record information:

• is a permanent record of the knowledge and skills you have
gained at work and during your training
• shows your trainer what training you have completed
• records details of your assessment against this unit.
It is the only record of the training and assessment you have

completed and it is essential that you keep it safe and clean.

Keeping track of your training
Your training record information
The training record information can help you keep track of all the training
you complete. You might:
• learn at home, at work, or somewhere else
• study one unit, several units, or the required number of units
to make up a complete Certificate
• have breaks in training
• move between Australian States and Territories
• change employers or workplace trainers.
In other words you can do your training how, when, and where it suits
you, but still make sure it counts, because the training record information
travels with you.
You will receive separate training record information sheets for each
Learner’s Guide. You should put all of your record sheets together in a
book or folder.
Remember, your training record sheets are valuable documents because

they may provide the only proof that you have successfully completed
particular units of competency. Your record sheets should be stored in a
safe place.
Your training log sheet
Your log sheet comes with your Learner’s Guide. You can use it to help
you and your supervisor or workplace trainer plan the activities you need
to do to complete your training. These may be special training tasks or
part of your normal duties. Your supervisor or workplace trainer will help
you use the logbook to make the most of your training opportunities.

How to use the assessment checklist and

record sheets
It is your responsibility to make sure that you:

• keep the assessment checklist and record sheets in a safe
place
• arrange for your workplace assessor to sign and date each
sheet after you have been assessed successfully. Make sure
your record sheets are always up to date. (Your assessor
might be the same person as your trainer but not necessarily).
Why is it important that your assessment is

recorded?
You may be assessed by different people and in different ways. The

assessment checklist and record sheets are used to make sure that all your
successful assessments are recorded. They should be stored in one place.
You will need a record of all your completed training and assessments if
you would like to work towards completing a certificate.
The assessment checklist and record sheets can also be used to record
assessments of the skills you have gained from other jobs or training. This
is called Recognition of Prior Learning (RPL) or Recognition of Current
Competence (RCC) and means you can be assessed without doing the
training but still make sure your skills are recognised. Speak to your
assessor, workplace trainer or supervisor if you think you would like an
RPL/RCC assessment.

How will you be assessed?
You could be assessed in many different ways. An assessor may:

• watch you perform your normal work duties
• set you specific tasks to do
• talk to you about how you normally perform your duties
• ask you specific questions
• ask you to assess your own strengths and weaknesses at work
• talk to people who are willing to speak on your behalf
• organise a formal test for a licence or certificate of
competence.
Assessors can also decide to:

• observe your performance more than once
• ask you to do some additional tasks
• ask you to show your skills in a slightly different way.
If you are not successful the first time you are assessed, you can:
• try again at another time
• ask your assessor, supervisor or trainer for more guidance
• do some more practice.
When you are successful, your assessor will record the assessment on
your training record sheet by dating and signing it. You should also sign it
at the same time.
What is the assessor’s role?
The assessor must:

• organise a place and time for the assessment with you, your
supervisor and your trainer
• give you feedback on your progress
• record the results of your assessments regularly
• date and sign your assessment checklist and record sheets.

Assessment checklist and record

sheets
The next section contains the assessment checklist and record sheets for
this unit. Your assessor will use this section to record the completed
assessment for the unit.
Remember to take this sheet with you when you are being assessed.


Assessment checklist and record

sheet
This assessment checklist and record sheet is for an assessment

against a single unit. If assessment is against a group of
competencies, an appropriate Assessment Kit will be used. These
are designed for assessment in occupational areas against a group
of related competencies.
Space is provided for additional or alternative assessment activities

to be recorded.

Learner’s details
Learner’s name
Workplace
Learner’s occupation/job
Relevant licenses (if required) sighted? YES NO
Assessment details
Assessor’s name and RTO details
Agreed date(s) for assessment

Assessor qualifications
Summary of assessment tasks

1. Check trailer suspension
2. Change a wheel
3. Replace a faulty globe
4. Replace a lens
Assessment result
Competent? Not yet competent?
Comment if NYC
Has the appeals process been explained to learner? YES NO

Has an appeal been requested? YES NO

Assessment details
NOTE:  indicates satisfactory performance or response
X indicates unsatisfactory or insufficient response or performance
DEMONSTRATIONS (Attach checklists used in assessments)
Summary of required  X Comments/observations by

performance assessor
QUESTIONING (Insert questions asked and summarise responses given)
Questions Responses  X

DOCUMENTS (Attach any documents produced for the assessment)
Document Comments  X
OTHER EVIDENCE
Add details of any further evidence sought from learner such as samples,
reports from supervisor or manager, workplace projects etc and comments on
suitability of evidence.
Details of evidence Comments  X
Signatures
As the learner I have been informed of the assessment result and the reasons
for the decision. I have been advised of appropriate follow up activity and the
appeals process.
Learner
Assessor
Date


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TLIB707C Carry

Additional resources ....................................................................... 53

Assessment tasks ........................................................................... 55

Feedback on activities .................................................................... 67

Training record information ........................................................... 71

Page 2 © Australian National Training Authority 2003

What this Learner’s Guide is about

© Australian National Training Authority 2003 Page 3

Planning your learning

Page 4 © Australian National Training Authority 2003

Section 1: Inspect the suspension and axles,

Are you able to: Yes No

Section 2: Inspect, adjust and make repairs to a

Are you able to: Yes No

© Australian National Training Authority 2003 Page 5

Section 3: Carry out repairs to the electrical

Are you able to: Yes No

Page 6 © Australian National Training Authority 2003

How you will be assessed

You will be required to:

© Australian National Training Authority 2003 Page 7

Page 8 © Australian National Training Authority 2003

Inspect the suspension and axle,

© Australian National Training Authority 2003 Page 9

Areas covered in this section

Identify various commercial vehicle trailer suspension types

Perform a service inspection on a commercial vehicle trailer

Perform a basic service inspection to a commercial vehicle trailer axle

Page 10 © Australian National Training Authority 2003

(a) Tapered single-­‐leaf spring (b) Tapered triple single-­‐leaf spring.

© Australian National Training Authority 2003 Page 11

Page 12 © Australian National Training Authority 2003

Lastosphere spring used as a booster spring

Sectional view of a rubber load cushion suspension

© Australian National Training Authority 2003 Page 13

Activity 1: What type of suspension does your trailer have?

What type of suspension is your trailer equipped with?

Page 14 © Australian National Training Authority 2003

Activity 2: Carry out a trailer suspension inspection on your

Carry out a trailer suspension inspection on your trailer. Only

Is the equipment in good condition? Yes No

Is the equipment in good condition? Yes No

Rubber suspension check the:

© Australian National Training Authority 2003 Page 15

Air suspension check the:

Ask your trainer for feedback on your inspection.

Page 16 © Australian National Training Authority 2003

Remove and replace hub oil seal on your trailer

Hub oil seal

© Australian National Training Authority 2003 Page 17

Axle assembly - exploded view

Axle assembly -­‐ exploded view

Oil seal installation

• Back off the adjusting nut counter-­‐clockwise approximately 60

• Raise the axle and remove the safety stands.

Page 18 © Australian National Training Authority 2003

Hub cap oil level indicator

• Release the parking brake and uncage the spring brake.

Remove, check, repack and replace and adjust

Trailer wheel bearing adjustment

© Australian National Training Authority 2003 Page 19

Page 20 © Australian National Training Authority 2003

Record all routine maintenance and repairs

© Australian National Training Authority 2003 Page 21

(a) Tapered single-‐leaf spring (b) Tapered triple single-‐leaf spring.

Axle assembly -‐ exploded view

• Back off the adjusting nut counter-‐clockwise approximately 60

Manual adjustment -‐ with drums installed