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This document is the copyright of Fairview Educational Services Limited and may not be reproduced in any form without its express written permission.

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Page 4 Keywords Page 5 Functions of a tyre Page 5 Tread patterns Page 7 Wheel rims Page 9 Australian design rules Page 9 Section Overview Page 10 Review Questions One Page 10 Protective clothing Page 12 Safety when working with wheels Page 15 Different ways to raise a vehicle Page 18 Safety when parking vehicles Page 20 Checking steering operation Page 20 Procedures to check wheel bearings Page 21 Procedures to remove wheels on the same axle Page 22 Inspection of tyres Page 22 Inspection of rims Page 23 Inspection of hub assembly

CONTENTS

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Page 23 Tyre Inflation Page 24 Refitting of the wheel to the vehicle Page 25 Section Overview Page 25 Review Questions Two Page 27 Wheel removal word search Page 28 Elements and Performance Criteria Remove, inspect and refit light vehicle wheel and tyre assemblies. What is this unit about Prepare to remove wheel and tyre assembly Remove and inspect wheel assembly and tyre assembly Refit wheel and tyre assembly Complete work processes How will I be assessed for these units? Assessment will take place when you are confident that you have acquired the skills and the underpinning knowledge necessary to successfully complete the unit. Practical skill assessment will take place only after a period of supervised practiced and repetitive experience. You must be able to meet all the requirements of this unit without direct supervision. Where can I find the Elements and Performance Criteria for this unit? Refer to the back of this workbook.

STANDARD AURLTJ003

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It is recommended that students learn the meaning and the correct spelling of the following key words that are particularly relevant to these unit standards. Wheel Tyre Valve Aspect Hydraulic Hoist Alignment Caster Camber Inflation Machine Tread Alloy Pressure Traction It is recommended that students are familiar with the following words and their definitions to help to understand the material contained in this workbook. Category: Class or group Dynamic: Relates to objects that are moving Static: Being at rest – no movement Efficiently: With no unnecessary effort or waste Diameter: A straight line segment passing through the centre Placard: A small display notice Symmetrical: Similar in size, shape and position Asymmetrical: Not similar in size, shape or position Liability: An obligation to pay an amount of money Specifications: Details of how something is to be built or used Ratio: Relationship in amount and size between two objects

KEY WORDS

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The main functions of a tyre are to: a) Cushion the ride b) Provide firm support for the vehicle c) Develop traction d) Help to maintain stable direction e) Absorb the impacts of accelerating, braking and turning Failure of a tyre to perform any of these basic functions may also impact on the safety of the vehicle and its occupants.

Tyre manufacturers’ produce a range of tyres with different tread patterns to enable a vehicle to operate in specific situations. This allows the vehicle to gain maximum surface contact while dispersing water, mud, snow etc. There are three main types of tread patterns: Symmetrical Asymmetrical All purpose (four wheel drive vehicles)

Symmetrical Tread Symmetrical tread is designed for performance, safety and high mileage under any road conditions. Their main feature is their ability to scatter water while travelling at high speed. They look the same from all angles and can be fitted on to either side of the car.

Asymmetrical Tread Asymmetrical tread is designed for all vehicles in all weather conditions. Tend to have good road handling and a long tyre life. They have different patterns on the outside zone of the tyre to the inner zone and are usually specific to either the left or right hand side of a vehicle.

All Purpose Tread (Cross Country) All-purpose tread is best suited to four-wheel drive vehicles that operate in extreme conditions over rugged land. The raised tread segments easily identify these tyres. The segments are raised in order to maximise grip and drainage. This tyre is not designed for high speed road use.

FUNCTIONS OF A TYRE

TREAD PATTERNS

High Mileage

All Weather

Rugged Land

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High performance tyres are directional tyres designed to enhance stability and handling at high speeds. TYPICAL CAR TYRES AND WHEEL RIMS

TYPICAL LIGHT COMMERCIAL VEHICLE TYRES AND WHEEL RIMS

TYPICAL HEAVY COMMERCIAL VEHICLE TYRES AND WHEEL RIMS

Run Flat Tyres Some vehicle manufacturers fit run flat tyres on particular vehicle models. These tyres have a thicker sidewall and a self-sealing lining that allows for the continued limited use of the vehicle in the event of a puncture. The vehicle can be driven up to a maximum of 80 km at a maximum speed of 80 km/h. Run flat tyres are not commonly used as they are expensive and if the puncture is in the sidewall they become ineffective.

Light vehicle

Utes and vans

Trucks and buses Ins

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Lightweight

A wheel rim is a metal circular component around which a tyre is fitted. The wheel rim is attached to the wheel hub and it is through this that the power generated in the engine can be applied to move the vehicle. As well as allowing the vehicle to move, the wheel rim and tyre assembly support vehicle loads. TYPES OF WHEEL RIMS The type of wheel fitted to a vehicle will depend on the cost, the performance and the load carrying requirements. PRESSED STEEL RIMS The most common and cheapest type of wheel rim used on cars and light commercial vehicles is the pressed steel rim. The wheel rim and the pressed steel centre discs are welded together. Steel rims have a rim well to enable easy fitting and removal of the tyres. A hole is located on the rim to allow the valve assembly to be fitted. There are holes cut into the disc near the rim to allow air to circulate and cool the brake assembly and also holes to allow the wheels studs and nuts to be fitted. The hole in the centre of the disc is used to align the wheel rim assembly onto the wheel hub. ALLOY RIMS Aluminium alloy wheel rims are manufactured using lightweight aluminium and magnesium alloys to form a strong and attractive wheel. They conduct heat faster than steel wheels. Alloy wheel rims however are more expensive than pressed steel wheel rims.

COMMERCIAL VEHICLE WHEEL RIMS Trucks and heavy commercial vehicles use a pressed steel rim or alloy rim to support the load they need to carry. These rims usually have a flat centre and a split rim to allow the tyre to be removed and re-fitted. MULTI-PIECE VEHICLE WHEEL RIMS Three piece wheel rim arrangements are commonly used in the car racing industry as offsets and rim widths can be quickly adjusted. They are also used for cosmetic reasons in the general retail market. They consist of an inner rim, outer rim and a wheel centre.

Welded rims

Split rim

WHEEL RIMS

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Rim width Rim flange

Safety ridges Well

Bead recess Diameter

SPOKED WHEELS In a spoke wheel/rim, the outside edge part of the rim and the axle mounting part are connected by numerous wires or spokes. Functions of Wheel Spokes The spokes can support the weight of the vehicle

They can transmit driving, braking and cornering forces

They enhance the look of the vehicle

They withstand occasional major shocks which could be caused by potholes or stones on the road surface

The most commonly used materials for making wheel spokes are: Aluminium

Carbon fibre

Magnesium alloy

Titanium

Spoke wheels should be inspected to ensure that all spokes fitted are not broken, bent or in any way damaged. If spokes require replacing, re-tensioning or repair these should be carried out by an approved repairer. WHEEL RIM MEASUREMENTS Wheel rims are manufactured to an agreed set of international standards and are identified by three measurements: 1. Wheel rim width 2. Flange height 3. Wheel rim diameter Wheel rims are also available in a number of different offsets. The offset measures the distance from the true centre line of the wheel rim to the mounting face positive or negative side of the centre. A negative offset wheel rim locates the wheel closer to the guard. A positive offset locates the wheel further under the car. TYRE PLACARDS Tyre placards specifying the tyre size, wheel rim size and tyre pressures that are recommended by the manufacturer are fitted to all new vehicles. WHEEL NUTS AND STUDS Wheel nuts are used to secure wheels by attaching and tightening the nut to the threaded wheel stud on the wheel hub. Wheel nuts and studs must be replaced if damaged.

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WHEEL WEIGHTS Varieties of wheel weights are available to fit different types of wheel rims and are used when correcting the static or dynamic balance of a wheel assembly. Wheel weights are made of lead and are either the clip on type (used for steel or alloy rims) or the adhesive on type (used for alloy wheels only). When balancing the wheel assembly the technician must select the appropriate wheel weight to attach to the rim. Wheel weights are usually measured in ounces.

The department of Transport and Regional Services, the National Transport Commission and representatives from the automotive industry in each state have developed performance and design rules for motor vehicle safety, emissions and/or anti-theft. The main ADR that relates to ‘remove, fit and adjust wheel(s)’ is: ADR 20.This rule requires that Australian vehicles are equipped with safety rims which will prevent a tyre from moving off the rim in the event of a sudden loss of air. SECTION OVERVIEW Tyres have several functions which all contribute to vehicle and occupant safety. Types of tyre tread patterns include: Symmetrical Asymmetrical All purpose

Types of wheel rims include: Pressed steel Alloy rims Commercial vehicle/split rims

Tyre placards provide information that is useful when changing tyres and wheels.

Key Points

Lead

AUSTRALIAN DESIGN RULES

Clip on wheel weights Adhesive type wheel weights

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REVIEW QUESTIONS ONE Q1 List the five main functions of a tyre: ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Q2 Outline the main features of an all purpose tread on a tyre: ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Q3 What is the function of the holes that are cut into the disc near the rim that are

found on pressed steel rims? ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Q4 What information can be found on tyre placards? ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ Q5 List the three measurements that are used when classifying wheel rims: ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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Overalls

Ear muffs

Steel Toe Cap

Safety boots

Protective clothing is designed to protect workers from injury. Areas of the body that need protection include eyes, ears, feet, body, head, lungs and hands. When using tools and machinery to change wheels it is the employee’s responsibility to use the machine guards and safety equipment provided. EAR PROTECTION Ear muffs should be worn when using a pneumatic gun to remove and refit wheel nuts. When exposed to prolonged high decibel noise there is a risk of industrial deafness. Industrial deafness is hearing loss that happens over a period of time and is painless, but permanent. Ear muffs are available in various grades. It is important to select the correct graded ear muffs for the noise level you are exposed to. PROTECTIVE FOOTWEAR When working in a workshop it is a requirement that safety footwear is worn. Remember wheel assemblies can be heavy, particularly for heavy vehicles. A safety boot is designed to: Support the foot and ankle joints. Protect the foot and toes from falling objects. Provide maximum grip. Standard safety boot consist of: Leather upper Non slip sole and chemical resistant Hardened steel toe-caps Heel protector Safety boots should be oil and water resistant and Standards Australia approved. BODY PROTECTION When working in a workshop it is a requirement that non-flammable overalls are worn. Remember used wheels and tyres can often be very dirty. Overalls are designed to: Be fire resistant. Protect the body from oil, grease and grime. The correct size overalls must always be worn. It is important that the overalls are strong and fit well. Avoid overalls with loose fitting cuffs, exposed belts and buckles.

Take Note *

Fire Resistance

PROTECTIVE CLOTHING

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Safety Gloves

HAND PROTECTION Safety gloves should be worn when working with wheels and tyres to avoid injuries from sharp edges and to prevent skin irritation. Dangers include: Exposed wire on tyres

Sharp edges on wheel nuts and treads Dirt build up on tyres and wheel assemblies Ideally leather gloves should be worn EYE PROTECTION Safety goggles should always be worn when there is a risk of eye damage. The risks when working with wheel assemblies include: Using pneumatic tools to remove wheels. This can

create a dust cloud which can irritate the eyes if not protected.

Inflating or deflating a tyre. There is always a danger

of a tyre exploding or debris exiting the tyre at speed.

It is important to be aware of safety issues when carrying out any of the following tasks: Selecting a tyre Jacking up a vehicle Removing a wheel Using a tyre machine Inflating a tyre Balancing a tyre Refitting a tyre

If tyre and wheel maintenance is ignored it could affect the safety of: All passengers

Other motorists

Pedestrians

Property

Good tyre and wheel maintenance and safety practices will: Prevent injury while working with tyres Prevent damage to the vehicle

SAFETY WHEN WORKING WITH WHEELS

Remove Jewellery

Clear Safety Goggles

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Sources of potential hazards when working with wheels in an automotive workshop: Compressed air and air operated equipment Heavy objects Jacking equipment Supporting equipment Hand and power tools

SPLIT RIM SAFETY PRECAUTIONS It is very important to appreciate the significant hazards that are associated when changing tyres with split rims. If the tyre explodes the wheel rim components become potentially fatal flying objects. The following safety precautions must be observed when changing tyres with split rim wheel assemblies:

WARNING Never over inflate a tyre Do not fit different size tyres to a vehicle Do not mix crossply tyres with radial tyres Never repair an illegal tyre

Very important safety points

Compressed Air and Air Operated Equipment Compressed air is used to operate air-powered machinery and to inflate tyres. When using this machinery avoid skin contact as the compressed air is under

extreme pressure and could cause severe pain and possibly death if compressed air entered the blood stream.

Do not allow any part of the body to become in contact with the moving parts of air-powered machinery as injuries can occur.

Never over-inflate a tyre or a tube. Use the manufacturers’ recommended inflation pressures. Tyres and tubes can explode if over-inflated.

When using air-powered equipment shield your eyes in order to avoid dust-flying particles.

Ensure that protective clothing (overalls, goggles, and ear muffs) is worn when using air- powered equipment.

WARNING Never remove split rim wheels from vehicles or unscrew any wheel nuts until

the tyre is deflated and the valve centre is removed. Never inflate tyres on a split rim unless the wheel is behind an approved

purpose built safety cage. Place the wheels centrally within the restraining guard. Inspect rims for defects before placing tyres on them. Ensure rim pieces are seated correctly. Inflate tyre slowly (no more than 35 kPa) and in stages. Check the rim after

each stage to ensure that is seated correctly. Never leave the air line attached unattended. Never repair an illegal tyre Never weld near or apply heat to split wheel rim assemblies Only trained staff should change, repair or service split rim tyres. Never hammer or bang split rim assemblies.



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Lifting Heavy Objects It is important to use the correct lifting techniques when lifting a wheel to avoid serious physical injuries. Remember to: Bend at the knees and crouch as close as possible to the wheel being lifted. Ensure that your back is kept straight while crouching. Grip the wheel firmly with both hands. During the lift maximise the use of your leg muscles. Avoid twisting the body or jerking the wheel from the vehicle. Place the wheel on the ground or on the machine using the same technique with

your legs. If you are unable to lift the wheel, STOP! Seek assistance or use lifting

equipment. Jacking equipment This includes: Scissors Jack Bottle Jack Trolley Jack Two and four Post Hoist

All of the items listed will have operating instructions either in the owner’s manual of the vehicle or on the machinery itself.

Supporting equipment It is important that when lifting a vehicle it is supported securely. Each vehicle has points where jacks hoists, or axle stands are to be placed, this ensures the vehicle is stable. This information can be found in the owners’ manual. Hand and power tools Always use the correct tools in the manner for which they were designed. Do not use alternatives or faulty equipment. Company Liability Technicians need to be aware that their employer is accountable for any damage caused to customer’s property as a result of the negligent actions of an employee. Where an employee deliberately damages property the employee will be prosecuted.

“Don’t Use Your Back as a Crane”

WARNING: Do not use any of these items until you have read the operating

instructions. Ensure that the lifting equipment used is not left protruding and creating

a potential hazard.


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DIFFERENT WAYS TO RAISE A VEHICLE Before raising a vehicle it is important to consult the owner’s manual to identify the correct jacking positions. These positions have been identified by the manufacturer as the strongest and safest jacking points. Scissor Jack This jack should only be used for the purpose of changing wheels on cars. Ensure that the scissor jack is in correct working order (lubricate threads annually)

Hydraulic bottle jack This jack is designed for the purpose of changing wheels on heavy vehicles. Have a professional check your hydraulic bottle jack annually.

Trolley jack and axle stands are used in an automotive workshop to raise and support a vehicle. They must be used together. The jack raises the vehicle to allow an axle stand to be positioned underneath each axle by a wheel. The weight of the vehicle must be supported by the axle stands rather than by the jack. The vehicle should be raised high enough to lift the wheels clear of the ground (this removes the possibility of the vehicle rolling off the axle stands). Before using axle stands ensure that each stand is in good working order. Check the security of the welds, check for any evidence of rusting, check that the feet are stable and that support mechanism is working properly. Check the load capacity of the stands. If raising just one end of the vehicle use wheel chocks at the opposite end of the vehicle to prevent the vehicle from rolling.

Scissor jack and jacking point Bottle jack

WARNING: NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY A JACK. ALWAYS SUPPORT THE VEHICLE USING AXLE STANDS.

Very important safety point

Trolley jack Axle stands

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Larger automotive workshops may be equipped with two and four post hoists. These hoists raise and support a vehicle fully, allowing for the convenient inspection of the under body. Two Post Hoist Raise the vehicle through its jacking points. This hoist allows the technician to remove wheels and carry out suspension servicing.

Four Post Hoist The four post hoist is a ramp device that supports the full weight of a vehicle. This hoist is ideal for carrying out wheel alignment servicing.

HAND TOOLS Always use the correct tools in the manner for which they were designed. Do not use alternatives or faulty equipment. Various kinds of hand tools are used in automotive workshops and their main purpose is to enable safe, accurate and speedy work. To achieve this you must select the most appropriate tools and know how to use them correctly. The manufacturer’s workshop manual must be read when selecting specialist hand tools to carry out automotive repairs. Specialist hand tools are precision made and should be used for a specific task only.

A vehicle supported on a four post hoist

A four post hoist ramp

A vehicle supported on a two post hoist

Position of two post hoist supporting arms

Raised using jacking points

Raised using ramps

Vehicle hoists

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Rules for using hand tools: 1. Select the most suitable tool to carry out the job safely and effectively. The tool

must be in good working condition and free from fracture and jagged edges. Repair or replace as necessary.

2. To reduce down time in searching for tools always return the tools to their correct position on the shadow board or in the toolbox.

Ensure that tools are kept clean and free from grease or oil. This will prevent the grease or oil from being transferred to the customer’s vehicle and will also assist the technician to maintain a firm grip on the tool. Common hand tools used when removing and replacing wheels include: Torque wrench Wheel brace TORQUE WRENCH A torque wrench is a calibrated tool that is designed to secure nuts and bolts to a specific turning pressure. The turning pressure or torque is measured by two measuring scales Newton metres (metric scale) and Foot pounds (imperial scale). There are three types of torque wrench that are commonly found in automotive workshops: Flex bar torque wrench Micrometer type Dial indicator It is important to apply the manufacturer’s securing sequence when tightening wheel nuts. This will prevent: Damage to the wheel nut threads. Wheel becoming too difficult to remove with a wheel brace. Wheel becoming loose during vehicle operation. After use, always reset the torque wrench to zero on the scale to prevent damage to the loading spring and inaccurate future settings.

Turning Pressure

Safety factors: Never over-torque a nut or bolt. Always pull the torque wrench

smoothly when operating Always pull the torque wrench when operating. Ensure sufficient clearance is given throughout the whole movement. Calibrate the torque wrench every 12 months. The torque wrench must be kept free from oil and grease. Store in original container

Securing Sequence


A torque wrench

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A Safely Parked Vehicle

Compressed Air

WHEEL BRACE A wheel brace is a useful tool in a break down situation for the removal and replacement of wheel nuts and wheel covers. It is commonly located in the spare wheel compartment of vehicles. As it is not a calibrated tool it is very difficult to achieve the recommended torque setting. AIR TOOLS The most common air tool used when removing or replacing wheels is the pneumatic impact wrench. This tool uses compressed air pressure to tighten or loosen wheel nuts. To achieve the manufacturers recommended torque setting always use a torque wrench. When using air tools remember to: Wear eye protection, ear muffs, boots

and overalls.

Ensure that the air hose is safe to use. Never use the compressed air gun to

clean overalls or brake and clutch parts.

Never point an air gun at another

person. When parking a vehicle in a workshop remember to: Maintain a hazard free workstation.

Watch for pedestrians and other

vehicles. Drive slowly. Position the vehicle appropriately for

the workshop. The vehicle should not cause a hazard in the event of an emergency.

Switch off the engine, select neutral

gear and apply the hand brake.

Ensure that there are no potential hazards before reversing, e.g. tools on the floor, protruding objects, people and other vehicles.

Be Alert

SAFETY WHEN PARKING VEHICLES

Turning Pressure

Operating a pneumatic impact wrench

A wheel brace

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RECYCLING To minimise cardboard and paper waste automotive workshops should strive to reuse boxes and packaging when storing and issuing parts. All waste should be stored for collection by the waste management disposal company. All tyres that are no longer fit for purpose must be stored for collection by the waste management disposal company. Tyres can be very damaging to the environment as they take hundreds of years to break down and can seep oil into the soil. Tyres can also pose a significant hazard in the event of a fire as they burn readily and produce a highly toxic smoke that is damaging to health and the environment. All waste products such as oils, chemicals, sludge and glass should be sorted and stored in the appropriate bins for recycling and disposal. Liquid waste must be drained into recycling containers. Dirty hands should be cleaned over drains that are connected to an oil-water separator or into drums for collecting liquid waste. WARRANTY It is important that before any work or diagnosis is carried out on a vehicle that the technician is aware of the vehicle warranty status. The technician needs to consider each of the following: Is the vehicle covered by a manufacturer’s warranty? Is the vehicle covered by a parts and service warranty? Has the owner taken out mechanical insurance? In general your supervisor will inform you of the warranty status of a vehicle. From the information provided the technician should be aware of the following:

The allocated labour time to complete the repair. The procedure for handling parts covered by the warranty. The procedures for recording the repair process, which will typically include

fault (the component that fails to operate), cause (why the component failed to operate) and remedy (process to repair/replace the faulty component).

Cost of Repair Once the fault has been diagnosed within the system the customer should be advised on two key points: 1. The feasibility of repairing the defective component. 2. The cost of a replacement component. The technician is responsible for determining whether a component can be economically repaired or whether it will need to be replaced. The technician’s diagnosis should be passed on to the workshop supervisor for consideration.

Insurance

Take Note *

Economic repairs

Tyres ready for recycling

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Checking wheel play

Company Liability Technicians need to be aware that their employer is accountable for any damage caused to customer’s property as a result of the negligent actions of an employee. Where an employee deliberately damages property the employee will be prosecuted.

Face the wheels straight ahead and check for free play in the tie rod end, wheel bearing and ball joints. Spin the wheel and listen for abnormal noise. There should be no abnormal noise or free play in the system. Repair, adjust or replace faulty components as necessary. 1. Apply the handbrake and ensure transmission is in park.

2. Place the jack in the correct position under the vehicle. 3. Raise the vehicle with the jack until the wheel lifts off the ground.

4. Check for play in the wheel bearings, tie-rod ends and ball joints. Check play by

grasping the wheel at the top and the bottom and rocking gently. The wheel assembly should feel firm.

5. Check for over tight wheel bearings by turning the wheel. If the wheel bearings are over tight the wheel will feel heavy and difficult to turn.

6. Check for wheel bearing roughness by rotating the wheel quickly and holding a suspension component (strut or spring). If there is a rumbling type sound or vibration wheel bearing roughness may be present.

Checking for wheel bearing roughness

PROCEDURES TO CHECK WHEEL BEARINGS

Free Play

CHECKING STEERING OPERATION

Take Note*

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Correct body position when removing a wheel

1. Apply the handbrake and ensure

transmission is in park. 2. Place wheel chocks at the opposite end of

the vehicle to be raised to prevent the vehicle from rolling

3. Place the jack in the correct position under the vehicle.

4. Raise the jack until the jack starts to lift the

vehicle. 5. Remove the wheel covers and loosen all the wheel nuts. 6. Raise the vehicle using the jack until the wheels lift off the ground. 7. Check that the vehicle is stable before proceeding. If unstable, reposition the

jack until a stable point is reached.

8. Position axle stands under the axle near each wheel. Gently lower the vehicle so that it is supported on the axle stands.

9. Use a wheel brace to remove the wheel nuts and carefully remove the wheels.

Store the wheel nuts in a parts tray. Road Side Servicing When changing a wheel on a public road observe the following safety precautions: 1. Wear a high visibility vest.

2. Drive to a lay by if possible, if not pull off the road. 3. Park the vehicle as far left as possible. 4. Place warning cones and triangles as per road code

instructions. 5. If the situation remains unsafe contact the police to

manage the traffic.

PROCEDURES TO REMOVE WHEELS ON THE SAME AXLE

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Tread worn down on one side

Feathering on tread pattern

A buckled wheel rim

The technician must inspect the tyre for evidence of damage and abnormal wear prior to refitting to the vehicle. If there is evidence of damage or wear a full inspection of the steering and suspension systems of the vehicle must be carried out. A wheel alignment may be necessary to rectify a tyre wear fault. A tyre may need to be replaced if any the following are present: Tread worn down Cracking Cuts Bulging Exposed tyre cords Uneven tyre wear Feathering Different tyres fitted to the vehicle

(size and make) Flat spots on the tread Sharp objects embedded in the tyre

The legal tread of a tyre must be 1.5mm deep or more at any point on the tread that is normally in contact with the road surface. Stones and other foreign material should be removed from the tread of the tyre. If the tyre deflates when removing the foreign object the technician should mark the entry point of the object with chalk as the tyre may be able to be repaired and re-used. The tyre valve should also be inspected for cracking, splitting, leakage and valve security. Replace as necessary.

With the wheel removed from the vehicle the technician must inspect the wheel rim for signs of damage. Should any of the following be evident the wheel rim wheel will need to be repaired or replaced: Inner or outer rim flanges are buckled Cracks in the welds of the rim Cracks in the wheel rim centres Cracks in the wheel nut seats Oval wheel nut seats Different size and make wheel rims fitted to

the vehicle Mud and dirt build up on the wheel rim

INSPECTION OF TYRES

Abnormal wear

Repair or replace

INSPECTION OF RIMS

Mark entry point

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With the road wheels off it will be necessary to inspect the wheel hub (flange) and mounting area for wear and any damage that may cause lateral or radial run-out. Lateral run-out occurs when the wheel travels from side to side during rotation. This will result in poor handling and excessive wear to suspension components. Radial run-out occurs when the wheel spindle travels up and down during rotation. This will result in steering vibration, out of balance and excessive wear to suspension components. A dial test indicator (DTI) is used to check for either of these wheel conditions. For checking lateral run-out the DTI is placed on one side of the rim and then on the side of the tryewall. For checking radial run-out the DTI is placed on the inside edge of the rim and then on a smooth section of tyre tread. Note the readings through full rotation of the wheel and compare with manufacturer’s specifications. If readings exceed specifications, deflate the tyre and reposition the tyre on the rim, inflate and recheck run-out. If run-out is still excessive the tyre or rim may need to be replaced. Ensure the wheel is dynamically balanced before refitting to the vehicle. Each wheel stud should also be checked to ensure that the wheel can be safely secured. Check for excessive wear and damaged threads.

Most tyre machines are equipped with a tyre pressure gauge. Before inflating a tyre on a tyre machine ensure that: The wheel is released from the wheel clamps on the turn table. The tyre is never inflated beyond the tyre manufacturer’s recommended

pressure. Bodily contact is not made with the tyre or with the wheel rim. During the inflation process release the pressure trigger regularly to monitor the

tyre pressure gauge until the recommended pressure is reached.

Under inflation Under inflation occurs when the air pressure in a tyre goes below the recommended inflation level. The centre of the tyre tread will not make contact with the road. This will wear out out both outside edges of the tyre and cause the tyres to roll on cornering. To remedy this fault, inflate the tyres to the correct inflation level.

TYRE INFLATION

Take Note *

Wear on both outside edges

Under Inflation (wear on outside edges)

INSPECTION OF WHEEL HUB ASSEMBLY

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1

2 3

4

Over inflation Over inflation occurs when the air pressure in a tyre is above the recommended inflation level. Both outside edges of the tyre will not make contact with the road. This causes excessive wear in the centre of the tread. To remedy this fault, deflate the tyre to the recommended inflation level.

Correct inflation The diagram shows a tyre with full tread contact on the road. This tyre tread will wear at an even rate. It is important to maintain the correct inflation level.

1 Locate the wheel studs to the wheel rim

2 Fit the wheel nuts and tighten by hand 3 Use the wheel brace to partially tighten the wheel nuts 4 Lower the jack slowly until the wheel is firmly on the ground. If the vehicle is

supported on axle stands raise the vehicle slightly to remove the axle stands before slowing lowering the vehicle to the ground. Ensure that the axle stands are well clear of the vehicle

5 Fully tighten the wheel nuts using a torque wrench and the correct tightening

sequence 6 Refit the wheel cover Wheel Nut Securing Sequence To secure the correct wheel fitment it is important to secure the wheel nuts in an opposing sequence. This action will avoid damage to the wheel.

4 Stud wheel 5 stud wheel 6 Stud wheel

Wear in the centre of the tread

Wears at an even rate

Correct Inflation (even wear across tread)

1 3

45

2

1

2

3

4

56 Securing sequence

Over Inflation (wear in the centre tread)

REFITTING OF THE WHEEL TO THE VEHICLE

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SECTION OVERVIEW Safety precautions must be observed when changing tyres and wheels in the workshop or on public roads. Only qualified staff should carry out wheel changes on vehicles fitted with split wheel rims. Before attempting to raise a vehicle the jacking points must be identified. Technicians should have an understanding of the legal requirements that apply to tyre condition. Incorrect tyre inflation will result in premature wear on the tyre tread. Under inflation leads to wear on the outside edges and over inflation leads to wear in the centre of the tread. Particular care must be taken to ensure that wheel nuts are tightened to specifications.

Key Points

REVIEW QUESTIONS TWO Q6 Explain two safety procedures to be followed when working with compressed air: _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q7 List five main points to remember when lifting a heavy object such as a wheel: _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ Q8 List three safety precautions that must be considered when inflating a tyre on a

split wheel rim: ______________________________________________________________ ______________________________________________________________ ______________________________________________________________

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Q9 Explain the purpose of vehicle lifting points: ______________________________________________________________ ______________________________________________________________ Q10 What is the legal requirement for tyre tread depth? ______________________________________________________________ Q11 What item of clothing should be worn when replacing a wheel on a public road? ______________________________________________________________ ______________________________________________________________ Q12 List five checks that should be made when inspecting a wheel rim? ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ Q13 Draw a diagram showing an over inflated tyre. Highlight the wear spots.

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TYRE REMOVAL WORD SEARCH

S A U L A G E E O Q

N R E T T A P N P Q

Q P O R P L H M G Q

Z O G S A H W V D T

L Z F C S O E B R M

P I A F H I P A Y R

T R E A D S C Z Z G

D F R F T T V S A W

U X Y E I L B R H W

T D T O Q V S E B I

Z X N Y L A E L N K

F Z Z K B L I Z X L

J N Z L V V A L K O

F W U U Y E B H V J

Identify the following words in the word search above:

Alloy Hoist Placard Pattern Scissors Traction Tread Tyre Valve Wheel

Identify the automotive terms scrambled below:

EOLRAICMMC _________________________________________ FNOILNTAI _________________________________________ UPLEZZ _________________________________________ YCIALUHRD _________________________________________ TSIOH _________________________________________

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ELEMENTS AND PERFORMANCE CRITERIA –AURLTJ003

ELEMENT NAME

Prepare to remove wheel and tyre assembly. AURLTJ003.1

1.1 Job requirements are determined from workplace instructions.

1.2 Removal, inspection and refitting information is sourced and interpreted. 1.3 Hazards associated with the work are identified and risks are managed.

1.4 Tools, equipment and materials are selected and checked for serviceability.

ELEMENT NAME

Remove and inspect wheel and tyre assembly. AURLTJ003.2

2.1 Wheel and tyre assembly is removed according to manufacturer specifications, workplace

procedures and safety requirements, and without causing damage to components or systems. 2.2 Wheel and tyre assembly, mounting points and fittings are inspected for condition, damage and

wear.

2.3 Inspection findings are reported according to workplace procedures, including recommendations for necessary repairs, replacements or adjustments

ELEMENT NAME

Refit wheel and tyre assembly. AURLTJ003.3

3.1 Refitting options are analysed and those most appropriate to the circumstances are selected. 3.2 Wheel and tyre assembly is fitted and adjusted according to manufacturer specifications,

workplace procedures and safety requirements, and without causing damage to components or systems.

3.3 Tightening sequence and torque settings are completed according to manufacturer

specifications and workplace procedures.

3.4 Wheel assembly is checked for correct assembly and run-out according to manufacturer specifications and workplace procedures.

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ELEMENT NAME

Complete work processes. AURLTJ003.4 4.1 Final inspection is made to ensure work is to workplace expectations and vehicle is presented

ready for use. 4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable

material is collected. 4.3 Tools and equipment are checked and stored according to workplace procedures.

4.4 Workplace documentation is processed according to workplace procedures.

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NOTES

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NOTES

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473 Te Rapa Road. PO Box 10-244, Hamilton 3241, New Zealand

phone 0064 7 849 9828 | fax 0064 7 849 9808 | [email protected] | www.fedsauto.com.au

Accredited and registered provider

EDUCATIONAL SERVICES LTD

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Documents

EDUCATIONAL SERVICES LTD Inspection - · PDF fileEDUCATIONAL SERVICES LTD ... Services Limited and may not be reproduced in any form without its express written ... aluminium and magnesium