City & Guilds sample training manual - Heavy Vehicle Service and Maintenance Technician Level 3

Apprenticeship Training Manual Level 3

Heavy Vehicle Service and Maintenance Technician 9302

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Contents

Welcome to the City & Guilds Training Manual Task mapping to apprenticeship standard Behaviours On-programme tasks: Year 1 Tools and equipment Progress tracking Task 1: Vehicle walkaround and familiarisation Task 2: Vehicle start up and shut down procedure Task 3: Safe lifting – wheels and torque wrench Task 4: Driver daily walkaround inspection Task 5: Cab access – lift, tilt and secure Task 6: Engine service inspection Task 7: Under vehicle service inspection Task 8: Standing height vehicle inspection Task 9: Hand skills – metalwork Task 10: Soldering and multimeter checks Task 11: Hydraulic and air pipe manufacturing Task 12: Electrical circuit board Task 13: Vehicle diagnostic scanner Task 14: Riveting Task 15: Lighting unit and bulb replacement Completed example: Lighting unit and bulb replacement

7 10 13 17 18 19 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55

On-programme tasks: Year 2 Tools and equipment Progress tracking Task 1: Air suspension bag Task 2: Suspension leaf spring Task 3: Steering track rod and track rod ends Task 4: Brake drum assembly Task 5: Brake disc assembly Task 6: Steering king pin hub Task 7: Wheel bearing Task 8: Rear axle half shaft Task 9: Driveline propshaft Task 10: Transmission gearbox Task 11: Fifth wheel coupling Task 12: Exhaust Task 13: Fuel injection

57 58 59 67 69 71 73 75 77 79 81 83 85 87 89 91

Task 14: Coolant and water pump Task 15: Compressor and air systems Task 16: Engine inspection Task 17: Starter motor Task 18: Alternator Task 19: Headlamp Task 20: Permanent magnet motor (any) Task 21: Diagnostic equipment

93 95 97 99 101 103 105 107

On-programme tasks: Year 3 Tools and equipment Progress tracking Task 1: Engine mechanical diagnostics Task 2: Turbocharger checks Task 3: On-board diagnostics (OBD) Task 4: Diesel fuel injection diagnostics Task 5: Emission control diagnostics Task 6: Water coolant diagnostics Task 7: Engine mechanical wear Task 8: Power take-off device (PTO) Task 9: Clutch hydraulic control Task 10: Final drive inspection Task 11: Gearbox inspection Task 12: ABS and brake pads Task 13: Brake line pressures Task 14: Steering king pin Task 15: Air suspension level control Task 16: Starting systems Task 17: Night heater Task 18: Alternator charging systems Task 19: Lighting systems

109 110 111 119 121 123 125 127 129 131 133 135 137 139 141 143 145 147 149 151 153 155

Years 1–3 The tasks in this manual have been organised into Years 1, 2 and 3. Successful completion of all the tasks to the end of Year 3 should indicate readiness for independent End-point Assessment. Employers and education and training providers should utilise the content of this document to assist in the design of the learning and development phase of the apprenticeship.

All apprenticehips consist of: on-programme phase, gateway and EPA. During the gateway the employer and the training organisation with the apprentice must agree that he/she is ready for end-point assessment and has achieved the level of skills, knowledge, behaviours, maths and English expected to successfully complete the apprenticeship.

The tasks in this manual have been developed to train and support apprentices. They can be completed more than once in order for them to gain confidence with their practical skills and gain the additional knowledge, behaviours and skills required to be ready for the End-point Assessment.

Welcome 

9

Stages of the apprenticeship journey On-programme – training for Year 1 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.

Annual review 1 The apprentice successfully completes • foundation skills • routine service inspection skills • annual evaluation.

On-programme – training for Year 2 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.

Annual review 2 The apprentice successfully completes • removal and replacement • intermediate diagnostics • annual evaluation.

On-programme – training for Year 3 The apprentice completes the on-programme tasks alongside an on-going review of their workplace soft skills and behaviours.

Final review The apprentice successfully completes • complex diagnostics • repair.

The trainer/mentor and employer review the training manual, annual elevations, behavioural evidence and confirm that the apprentice is ready for the End Point Assessment.

10

Level 3 Heavy Vehicle Service and Maintenance Technician 9302

Group 3: Complex diagnostics and repair

Group 2: Removal and replacement and intermediate diagnostics

Group 1: Foundation skills and routine service inspection skills

Induction to programme

Continuous behaviour and review interviews

Task cross reference to unit groupings.

This supports the competence linked to the knowledge requirements.

Task mapping to the apprenticeship standard

Year 1 training 1 Vehicle walkaround and familiarisation 2 Vehicle start up and shut down procedure 3 Safe lifting: Wheels and torque wrench 4 Driver daily walkaround inspection 5 Cab access: Lift, tilt and secure 6 Engine service inspection 7 Under vehicle service inspection 8 Standing height vehicle inspection 9 Hand skills: Metalwork

2.1 2.2 2.3

1.1 1.4 1.5

2.1 2.2 2.3

1.1 1.2 1.4 1.5

2.1 2.2 2.3

1.1 1.2 1.4 1.11 3.1

2.1 2.2 2.3

1.1 1.2 1.4 1.5 1.6 1.9

2.1 2.2 2.3

1.1 1.2 1.4 1.6

2.1 2.2 2.3

1.1 1.2 1.3 1.4 1.6 2.1 2.5 2.6 2.7

2.1 2.2 2.3

1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.5 2.6

2.1 2.2 2.3

1.1 1.2 1.3 1.4 1.5 1.6 2.1 2.5 2.6

2.1 2.2 2.3

2.1 1.4

10 Soldering and multimeter checks 11 Hydraulic and air pipe manufacturing 12 Electrical circuit board

2.1 2.2 2.3

2.1 2.3

2.1 2.2 2.3

1.1 1.2 1.4 3.12.3

2.1 2.2 2.3

3.1

13 Vehicle diagnostic scanner 14 Riveting

2.1 2.2 2.3

1.1 1.2 1.3 1.4 2.1 2.3 2.4 2.6

2.1 2.2 2.3

2.1 2.3 1.4

15 Lighting unit and bulb replacement

2.1 2.2 2.3

1.4 1.2 1.6 2.1 2.3 2.6

Task mapping to the apprenticeship standard 

11

Year 1: Skills training programme

Task groupings Group 1 – Behaviour skills development Group 2 – Engineering foundation skills development Group 3 – Heavy vehicle routine inspection skills development

Year 1: Skills training programme

17

Tools and equipment

The following is an example of the necessary resources, tools and equipment needed to support the practical skills for Year 1.

18

■■

Garage tool box/kits: spanner, sockets, screwdriver, hammer

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Torque wrenches – ¼, 3/8, ½ and 1 inch drive

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Coolant pressure test equipment

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Computer diagnostic interface

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Ammeter (multimeter) and a separate amp clamp

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Voltmeter (multimeter)

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Ohm meter (multimeter)

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Headlamp alignment

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Typical garage ¼, 3/8, ½ and 1 inch drive socket sets

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Impact drivers – air, electric

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Lifting equipment – vehicle ramps, jacks and stands

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Hand lamps – safe voltages required

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Electrical circuit boards equipment

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Drill, drill bits

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Files, punches, general metal workshop tools

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Circuit board for 3 x bulb multimeter checks

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Allen® keys

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Soldering iron

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Rivet gun and rivets

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Spline and Torx® sockets

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Pullers

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Air line

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Measuring equipment – micrometer, ruler, vernier, DTI

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Vehicle protection covers – internal and exterior

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Consumables – nuts, washers, bolts, wire terminals

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Gasket paper, gaskets

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Grease, oils, sprays, sealants

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Antifreeze

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Data source for vehicle information

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Oil change drain equipment

■■

Road wheel removal trolley

Level 3 Heavy Vehicle Service and Maintenance Technician 9302

Progress tracking

1 Vehicle walkaround and familiarisation Feedback where necessary

Trainer/mentor signature:

Date of completion:

2 Vehicle start up and shut down procedure Feedback where necessary

Trainer/mentor signature:

Date of completion:

3 Safe lifting – wheels and torque wrench Feedback where necessary

Trainer/mentor signature:

Date of completion:

Year 1: Skills training programme 

19

Task 4: Driver daily walkaround inspection

Apprentice name:

Task start date:

Conduct a driver daily walkaround inspection. You will need to use an inspection sheet for this task. You must work safely in an automotive workshop, following correct health and safety requirements. You must follow all health and safety procedures in an automotive workshop and wear the correct PPE. Data and equipment to be used Apprentice to complete before starting. Assessor to tick if used correctly.

✓

Vehicle make Vehicle model Year of manufacture Type of vehicle (tractor unit, rigid vehicle) Skills and behaviours Assessor to tick if followed effectively.

✓

Implement the foundations of each of the behaviours from the standards Behave in accordance with the values of the company worked for Operate effectively as a team member Work at continuous development of self, team and processes Mandatory tasks and information to complete Brake lines

✓

Electrical connectors Mirrors/glass/front and rear view Brakes and air pressure tank checks Steering operation Horn, wipers, washers, indicators and information Exhaust smoke Fuel tank/leaks Wheels/tyres and markers, spray suppression Lights, reflectors and markers Body and load security Battery security Completed and checked

Year 1: Skills training programme

31

Apprentice report on Task 15 completed example: Lighting unit and bulb replacement Provide a brief written report of the procedures carried out to include the following criteria.

1 Risk assessment.

2 Correct use of tools used.

3 Overall self-evaluation of finished product, including a report of any damage.

Apprentice report

The task involved removing the rear lighting cluster from the near side mud and spray unit. This involved removing the lens cover and the supporting 4 mounting nuts and bolts. The risk identified was to make sure the area was clean and safe, also the lights switched off during removal. I also informed others where I was working.

While the lens cover was removed it was identified that conventional bulbs were not fitted. Instead, a series of LEDs were fitted as marker lights. This unit was refitted while the lens was off. I checked the lighting system to ensure that all lights functioned correctly.

The lens was fitted back with 6 set screws and made secure.

All the tools were put back in the toolbox correctly and the floor area was swept up.

I wore correct PPE at all times, also worked with the manager to check my work to set standards. I worked with Ernie Edwards who held the lamp and tools and switched the lights on for me.

Trainer/mentor feedback Task completed safely with risks identified, good communication shown with colleague. All the removal and refit exercise completed to a very good standard. Ernie and Tommy worked very well together. Lights checked and task completed.

Trainer/mentor signature:

Apprentice signature:

56 

Joseph Smith

Tom Atkins

Level 3 Heavy Vehicle Service and Maintenance Technician 9302

Date: 28/03/2017

Date: 28/03/2017

125006184 TL9302

ISBN 978-0-85193-400-6

9 780851 934006

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