How to use this resource - Kanganlrd.kangan.edu.au/auto/downloads/AURT202166A/AURT2… · Web viewaur30405 certificate iii in automotive mechanical technology. aur30405 certificate

AUR30405 CERTIFICATE III IN AUTOMOTIVE MECHANICAL TECHNOLOGY

AURT202166A Repair cooling systems

TRAINER GUIDE

© Commonwealth of Australia 2011

ISBN: 978-1-876838-55-3

This document is available under a “Free for Education” licence for educational purposes – see http://www.aesharenet.com.au/FfE2 for details.

This work is copyright. You may download, display, print and reproduce this material in whole or in part or in modified form (retaining this notice) for your personal, non-commercial use or use within your organisation. If you use, display, or reproduce this material or a modified form of it in whole or in part within your organisation you must include the following words in a prominent location within the material in font not less than size 12: ‘The views expressed in this publication do not necessarily represent the view of the Minister for Education or the Australian Government. The Australian Government does not give any warranty nor accept any liability in relation to the contents of this work’. Apart from any use as permitted under the Copyright Act 1968, all other rights are reserved. Requests and inquiries concerning reproduction and rights should be addressed to the Commonwealth Copyright Administration, Attorney General’s Department, Robert Garran Offices, National Circuit, Barton ACT 2600 or posted at http://www.ag.gov.au/cca.

Funded under the Workplace English Language and Literacy (WELL) Program by the Australian Government Department of Education, Employment and Workplace Relations.

The views expressed in this publication do not necessarily represent the view of the Minister for Education or the Australian Government. The Australian Government does not give any warranty nor accept any liability in relation to the contents of this work

http://www.aesharenet.com.au/FfE2

1

How to use this resourceThis learning resource will assist a trainer to deliver lessons for this competency. The Trainer’s Guide, PowerPoint and Learner Workbook support the delivery of the competency, and the Assessor Checklist assists with the learner’s assessment.

Trainer’s GuideThe Trainer’s Guide is divided into learning topics and contains information and strategies that guide the trainer through each step of the content delivery.

It also contains some suggestions for working successfully with learners who have difficulty with language, literacy and numeracy (LLN).

The Assessor Checklist supports the assessment of the learner’s competence. This Checklist can be used in both a training environment and the workplace. Using this document assists the trainer to assess a learner’s practical skills and their underpinning knowledge in a valid and consistent manner.

PowerPoint presentationThe PowerPoint presentation should be used to enhance the delivery, for example:

to discuss a diagram, procedure or concept as a group

to explain a process in more detail to a group

to invite and answer questions regarding a particular topic.

Learner WorkbookThe Learner Workbook style and content is designed to be as clear and accessible as possible for the learner.

Activity sign-off points are located in the workbook to enable the trainer to monitor the learner’s progress and understanding.

Icons used in this guide

PowerPoint presentation

Video clip

Access and equityPeople with differing needs and abilities should have the same opportunities to successfully gain skills, knowledge and experience through education and training. Trainers and their organisations should work to remove barriers and provide the supports people need to access, participate and achieve, irrespective of their age, disability, colour, race, gender, religion, sexuality, family responsibilities or location.

For students with disabilities, training organisations may make adjustments to ensure equal opportunity. Reasonable adjustments are designed to minimise the disadvantage experienced by learners with a disability and can include administrative, physical or procedural modifications.


2

How can you identify learners with LLN needs? Adults with language, literacy and numeracy (LLN) problems often wish to avoid identifying themselves. They may have developed effective strategies to conceal their problems and manage in daily life.

Learners having trouble with the literacy or numeracy of a task may:

ask for help often

never ask for help to avoid drawing attention to themselves

avoid doing the task

use coping strategies for getting around the task

display inappropriate behaviours to divert attention from the task.

How should you approach learners with LLN needs? The following qualities should inform your dealings with these learners:

Tact – the learner is in a vulnerable position.

Respect – they have risked returning to a formal educational setting.

Confidentiality – a private chat is a much better strategy than pointing out the learner’s difficulties to them in front of other learners.

Supportiveness –you are in a position to encourage a learner who may previously have experienced failure and criticism in educational settings.

Openness - Full explanation of any formal strategies (such as extra classes or an alternative pathway) is important to ensure the learner fully understands their own needs and the reasons for any advice you may give them.


3

Some training strategies for learners with LLN needsBe aware of the LLN needs of your learners and adapt your training strategies to maximise their chances of learning.

Here are some strategies that support learners with LLN needs.

1. Design of resources Check the language level of your resources. Make sure it is no

higher than the level required by the qualification and the job.

2. Teaching practices Use oral activities such as discussion, question & answer, and

demonstration as well as reading and written activities.

Don’t overload the learners with large amounts of information. Present it in manageable chunks. Break tasks down into smaller steps to make them clearer.

Teach the language of the workplace explicitly. Introduce new terms clearly. Explain exactly what they mean, even if you think it is obvious and everyone should know it.

Write new words and key words on the whiteboard as they arise. Explain them and give learners time to copy them down if they want to.

Scaffold any writing tasks. Provide a skeleton of a model and the learners add the details. As learners’ skills develop, reduce the amount of structure provided, requiring them to do more themselves. This gives learners a framework to use until they feel confident to do a writing task independently.

Practice writing often. Provide opportunities for repeated practice of required writing tasks, initially supported /scaffolded and then independent practice.

3. Learner management When in a classroom setting, arrange the furniture so everyone

can see and hear easily. This also creates a sense of personal connection with the trainer, rather than a feeling of being invisible in a large group.

Encourage learners to ask questions. Point out that this is how we learn, and that it is not a sign of failure but a strategy that the best learners use.

Check regularly that learners have really understood the material you are presenting. Don’t just ask, “Have you got that?” Ask them to actively use the information in some way e.g. give an example, retell it in their own words, or answer a specific question.

Be alert for non-verbal signs that a learner doesn’t understand e.g. confused looks, frowning, leaning over to ask a neighbour, spending a lot of time doing preliminary arranging instead of tackling a task, never volunteering to answer a question.


REMEMBER:The LLN level of the training, resources and assessment tasks should be no higher than that of the work learners are training to do.If learners have trouble reading questions and/or writing answers, and the LLN level required is above what they would need in their workplace, then oral questions and answers should be used as a substitute.

4

Content Delivery guide

Video clipsThe video clips referred to in this Guide are from a commercial provider of automotive training resources called CDX Global http://www.cdxglobal.com/ . Many Australian automotive RTOs subscribe to CDX and use some combination of their resources, and the videos referred to here are an excellent enhancement of training.

However they are not critical to a successful training outcome. Video clips from other sources, hands-on demonstration and ‘home-made’ videos using flip cameras or similar are all good substitutes.

Below are the CDX videos suggested for use in this unit:

Video Title CDX Number

Cooling systems 2201

Heat transfer 2101

Cylinder head construction 2301

Water pump operation 4301

Thermostat 4401

Fans 4501

Radiators 4101

Radiator hoses 4201


http://www.cdxglobal.com/

5 © Commonwealth of Australia 2011

6

Delivery GuideTOPIC INFORMATION METHODOLOGY RESOURCES

Introduction Repair cooling systemsProvide learners with an overview of the main topics to be covered in this competency and how it will relate to other competencies and their own skill development

Oral presentation Example of different types of cooling

system used in vehicles in the automotive industry

PPT slides 1 & 2

Types of vehicles

Cooling systems

(CDX Video 2201)Learner workbook p. 6

Cooling system function Main function of cooling system Oral presentation Describe the main function of the cooling

system

PPT slide 3

Heat in enginesLearner workbook p. 6

Liquid cooling operation

What is a liquid cooling systemTypes of vehicles that use themHeat transferSystem operationComponent function

Oral presentation Describe the types of vehicle that use this

system, why must heat transfer be managed

How does the system operate? What are the functions of the systems

components?

PPT slide 5

Engine temperatureHeat energyLearner workbook p.7

Heat transfer

(CDX Video 2101)


7

TOPIC INFORMATION METHODOLOGY RESOURCES

Liquid cooling construction

System componentsDescribe/identify components

Oral presentation Visual displays Running engines Dismantled components(preferably

sectioned)

PPT slide 6

Cooling system componentsLearner workbook pp. 8-9

Activity 1 Learner to complete Activity 1 in workbook.Conduct review of questions and discuss

Learners answer questions 1-6 Learner workbook p. 11

Engine coolant safety Use Learner workbook for Learners to read caution statements and highlight safety precautions

Oral presentation Learner workbook caution statements Explain four main steps to remove radiator

cap.

PPT slide 7 & 8

Learner workbook pp. 14-15

Activity 2 Learner to complete table in workbook.Conduct review of questions and discuss.

Point out the headings in the MSDS.Encourage and assist learners to write main points only, not copy out paragraphs.

Learner workbook p. 16MSDS for engine coolant

Cooling system testing & diagnosis - External

ExternalRefer to p18 Learner workbook for cooling system components to check.Emphasise leaks inside cabin (heater core)

Oral presentation Cover main points p17-p18 Learner

workbook Perform testing procedure

PPT slide 10

Radiator with test equipment with adaptorsStationary or running engineLearner workbook pp. 16-19


8


Cooling system testing & diagnosis - Internal

C02leak detector

Use example of effects of internal leaks.Explain how minor head gasket leaks will develop into major engine repairs if not controlled or detected early.Explain head check unit operating procedure.Use an engine in good operating condition and demonstrate test fluid colour change using exhaust gas sample.

Oral presentation Visual display of damaged heads and

gaskets Perform testing procedure/demonstration

PPT slide 11

Radiator with test equipment with adaptorsStationary or running engineCylinder headCylinder gasketLearner workbook pp. 20-24

Activity 3 Learner to complete questions 1-5 in workbook.Conduct review of questions and discuss.Workshop activity to complete checklist.

Oral presentation Learners answer questions 1-5 Explain assessment requirements of cooling

system checklist Completing the checklist part of the activity

can be done by a group or individual

PPT slide 12

Learner workbookAccess to a workshopRunning enginesHead check unit pressure test kitLearner workbook pp. 26-29

Cooling system repairs

Cooling system flushing

Reverse flushing

Explain minor serving to avoid major repairs.Highlight information about inhibitors used contain chemicals.Explain how the reverse flushing process operates.

Oral presentation Explain procedures for safe flushing of

cooling system Emphasise points from PPT slide

PPT slide 14


Engine block flush Explain steps to reverse flush an engine block.

Oral presentation Demonstrate reverse flushing operation

Flushing equipmentSimulated work areaWorkplace environmentLearner workbook p. 34-35


9


Activity 4 Learner to complete questions in workbook.Conduct review of questions and discuss.

Oral presentation Learners answer questions Explain assessment requirements of reverse

flushing engine


Activity 5 Workshop activity to complete reverse flushing of engine.Select tasks for learners to complete.

Learner workbook p. 39Access to a workshopRunning enginesFlushing equipment

Welsh plugs Use cylinder head video to explain the function of Welsh Plugs

Explain types of Welsh plugs Explain the removal and

replacement procedures

Oral presentation Types of Welsh plugs Demonstrate removal and replacement of

welsh plugs

PPT slide 15

Cylinder head construction

(CDX Video 2301)Learner workbook pp. 40-43Access to a workshopRunning enginesApplicable tools and equipmentDifferent types of Welsh plugs

Activity 6 Learner to complete questions 1-2 in workbook.Conduct review of questions and discussQuestion 3 - Workshop activity to complete remove and replace water pump

Oral presentation Learners answer questions 1-2 Explain assessment requirements of

removing and replacing water pump

Learner workbook p. 44Access to a workshopRunning enginesWater pumpsTools and equipment


10


Water pump Water pump operation Effects of damaged, worn pumps Testing of water pumps Removal and replacement of

water pumps

Oral presentation Operation Effects of damaged, worn pumps Testing pumps Procedure for removal and replacement of

pumps

PPT slide 16

Water pump operation

(CDX Video 4301)Learner workbook pp. 46-50.

Activity 7 Learner to complete questions 1-4 in workbook.Conduct review of questions and discussQuestion 5 - Workshop activity to complete remove and replace water pump



Learner workbook pp. 52-54Access to a workshopRunning enginesWater pumpsTools and equipment

Thermostat Function and operation of thermostat

Effect of faulty thermostats Types of thermostats Remove, test and replace

thermostats

Oral presentation Types of thermostats Demonstrate removal and replacement of

thermostat

PPT slide 17

Thermostat

CDX Video 4401Learner workbook pp. 55-60Access to a workshopRunning enginesApplicable tools and equipmentThermostats


11


Activity 8 Learner to complete questions 1-8 in workbook.Conduct review of questions and discussQuestion 9 - Workshop activity to complete remove, test and replace thermostat



Learner workbook pp. 62-64Access to a workshopRunning enginesThermostatsTools and equipment

Cooling fan Cooling fan operation Explain shift from fixed to viscous

cooling type fans Electric fans Effects of cooling fans not

operating

Oral presentation Operation Types of cooling fans Effects of cooling fans not operating

PPT slide 19

Fans

(CDX Video 4501)Learner workbook pp. 66-67Access to a workshopRunning enginesApplicable tools and equipmentTypes of cooling fans

Activity 9 Test cooling fan Use appropriate workshop

manual procedures and available test equipment.

Learners complete workshop tasksExplain assessment requirements of diagnosing cooling fan faults

Learner workbook p. 68Workshop manualsAccess to a workshopRunning enginesTypes of cooling fansTools and equipment


12


Removing and replacing coolant hosesRemove and refit radiator

Checking coolant hosesRemove and refit coolant hosesRemove and refit radiator

Oral presentationOperationTypes of coolant fansDemonstrate remove and refit coolant hosesDemonstrate remove and refit radiator

PPT slide 20

Radiators & Radiator hoses

CDX Video: 4101 & 4201Learner workbook pp. 70-74Access to a workshopRunning enginesApplicable tools and equipment Coolant hoses

Activity 10 Remove and refit coolant hosesTest cooling fanRemove and refit radiator

Learners complete workshop tasksExplain assessment requirements of remove and refit coolant hoses and radiators

Learner workbook pp. 75-77Workshop manualsAccess to a workshopRunning enginesCoolant hosesradiatorsTools and equipment

Activity 11 Fill system with coolantBleed system Pressure test system for leaks

Learners complete activity checklist Learner workbook p. 79Workshop manualsAccess to a workshopRunning enginesCoolant hosesRadiatorsTools and equipment


13


Glossary Learner workbook pp. 80-81


14

ASSESSOR OBSERVATION CHECKLISTUnit of competency: AURT202166A - REPAIR COOLING SYSTEMS

Instructions for the assessor:1. Identify a vehicle on which the candidate can perform the practical tasks2. Observe the candidate perform the practical tasks.3. Place a tick in the box to show that the candidate has completed each practical task competently.4. Whilst carrying out the practical tasks ask the candidate a selection of the questions from the

attached list. This is to:a. confirm their ability to relate underpinning knowledge to practical situationsb. identify their ability to transfer practical skills to various vehicles/situations.

5. Place a tick in the box to confirm that candidates answered the questions correctly.6. Complete the feedback sections of the form.

Type of vehicle &/or equipment &/or system

Work performed

Date of observation

OBSERVATIONSThe applicant is able to:

1. Correctly observe OH&S requirements during task. 2. Select and correctly use PPE for task. 3. Select and correctly use the appropriate tools for the task. 4. Demonstrate knowledge of the dangers of working with cooling systems. 5. Observe danger warnings during task. 6. Access and use manufacturer’s specifications relevant to task. 7. Access and use appropriate test equipment for task. 8. Carry out test procedures in accordance with workplace procedures and manufacturer’s

specifications.

9. Carry out repair procedures in accordance with workplace procedures and manufacturer’s specifications.

10. Analyse and compare test results with manufacturer’s specifications. 11. Document test results and makes relevant repair recommendations. 12. Implement repair methods in accordance with workshop procedures and

manufacturer’s specifications.

13. Return tools, equipment and resources correctly. 14. Implement adjustments in accordance with workshop procedures and manufacturer’s

specifications.

15. Complete repair report correctly. 16. Carry out final inspection of completed task. 17. Leave work area in a safe and tidy state.


15

ASSESSOR OBSERVATION CHECKLIST

Did the candidate’s overall performance meet the standard? Yes No

Feedback to candidate

General comments / Strengths / Improvements needed

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

Candidate signature: __________________________________ Date: ____/____/20___

Assessor signature: __________________________________ Date: ____/____/20___


16

ASSESSOR QUESTIONS

Questions to probe the candidate’s underpinning knowledgeSatisfactory

response

Yes No

1. Why is it important to follow OH&S guidelines?

2. What PPE will you use for this task?

3. What tools will you use for the task?

4. Describe some dangers of working with cooling systems.

5. Where will you find the manufacturer’s specifications for coolant task?

6. How do you know that the test equipment is accurate?

7. Describe how you would test the radiator cap.

8. Describe the correct procedure to pressure test the cooling system.

9. Describe how a thermostat operates.

10. What is the function of coolant inhibitor?

11. Describe at least one method to check for a leaking cylinder head gasket.

12. How would you correctly seal replacement welsh plugs?

13. Where would you find the correct procedures for cooling system repairs?

14. Why is it important that the repair worksheet is correctly completed?

15. Why should the tools, equipment and resources be returned to designated storage?

16. Why should the work area be left in a safe and tidy state?


17

ASSESSOR QUESTIONS

The candidate’s underpinning knowledge was: Satisfactory Not satisfactory

Feedback to candidate

General comments / Strengths / Improvements needed

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

Candidate signature: __________________________________ Date: ____/____/20___

Assessor signature: __________________________________ Date: ____/____/20___


Documents

How to use this resource - Kanganlrd.kangan.edu.au/auto/downloads/AURT202166A/AURT2… · Web viewaur30405 certificate iii in automotive mechanical technology. aur30405 certificate