Level 3 Light Vehicle Technology iResource Guide - Pearson Schools

13 Pages·2012·2.65 MB·English

HEINEMANN
Work-Based Level 3
Diploma
Learning
prinCiples of
ligHt VeHiCle
teCHnology
ALWAY S L E A R N I NG
Authored by Graham Stoakes and moulded around the 2010
specifcation, these resources are designed to continue
seamlessly from levels 1 and 2 and pave your learners’ way
to successful careers in the automotive industry.
introduCtion
We’Ve made eValuation easy for you
WitH tHis resourCe guide
step 1: Take a look at the sample material* in this guide
showing our new level 3 resources and see how they
will work for you and your candidates
step 2: If you are ready to order, visit
www.pearsonfe.co.uk/Level3LightVehicle
step 3: If you still want to know more, the why not set up a
visit from one of our sales consultants? See the back
cover for details.
* All the materials in this resource guide are draft samples
and are subject to fnal correction before publication.
2
Candidate Handbook:
l Designed specifcally for your level 3 learners to
provide an accessible, relevant and professional
handbook that helps candidates progress in their career.
l Helps learners focus on diagnostics and rectifying faults
as a progression from level 2.
l Covers the latest technology within the industry which not only
Candidate Handbook
provides the knowledge and skills to pass the qualifcation,
but is highly relevant to the workplace.
l Problem-solving features help put theory into practice
and better prepare candidates for the world of work.
l Highlights employability skills in a range of focused case studies.
Contents:
CHapter 1 Introduction to light vehicle technology / diagnosis and rectifcation
CHapter 2 Diagnosis and rectifcation of light vehicle chassis system faults
CHapter 3 Diagnosis and rectifcation of light vehicle engine faults
CHapter 4 Diagnosis and rectifcation of light vehicle auxiliary electrical faults
CHapter 5 Diagnosis and rectifcation of light vehicle transmission and driveline faults
CHapter 6 Identifying and agreeing motor vehicle customer service needs
index
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Candidate Handbook
Level 3L eLvigehl t2 VNeVhQic/lSeV TQe cDhipnlolmogay Brickwork 3rd edition
Key term To diagnose hydraulic system pressure faults, you must fi t a power-
In series – incorporated assisted steering pressure gauge in series with the pump, then run the
as part of the circuit. engine at different speeds and under different operating conditions.
The gauge is similar in operation to an engine oil pressure gauge, but it
has a manually operated valve that is able to control the fl ow of fl uid in
the system. In this way, you can check fl ow and pressure and compare
them with the manufacturer’s specifi cations.
∑By connecting the gauge with the valve in the open position, you can
check supply pressure when the steering is at full lock.
∑By connecting the gauge with the valve in the open position, you can
check supply pressure when the engine is operating in its normal
rev range (1000 to 3000 rpm) with the steering in the straight ahead
Technology evolves quickly position.
in the engineering world and ∑By connecting the gauge with the valve in the closed position, you
can check the maximum supply pressure available from the pump.
our NEW TECH sections keep
learners up to date on the
latest developments.
Figure 2.43 Using a gauge to check steering hydraulic pressures
NEW TECH
Steer by wire
Some manufacturers are experimenting with a system of steer by wire. In this set up,
the steering wheel is replaced with a joystick that can control not only steering but also
acceleration and braking. The main drawbacks of this system are the diffi culty in making it
failsafe and the reluctance of drivers to give up control of the steering wheel.
Safe working sections provide
Safe working learners with health and safety
Action
Do not run the hydraulic pump for more than fi ve seconds with the valve on the pressure
Examine a vehicle in your gauge in the closed position, as this may cause the pump to overheat and can cause damage. best practice so injuries can be
workshop and identify the main
component parts of a hydraulic Power-assisted hydraulic fl uid pressures can reach around 80 bar (1160psi) so you must take avoided.
power-assisted steering system. care when working on these systems.
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Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
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Candidate Handbook
2 Diagnosis & rectifi cation of light vehicle chassis system faults
Table 2.7 Typical operating pressures that may be found during hydraulic testing
Pressure gauge valve open Pressure gauge
valve closed
Engine speed Engine speed Engine speed Engine run
1000 rpm 3000 rpm 1000 rpm, steering (maximum Symptom and possible
turned to full lock 5 seconds) fault
40 bar 35 bar 80 bar 80 bar Correct operation
25 bar 25 bar 80 bar 80 bar Power assistance too low
Flow control valve stuck
open/faulty
40 bar 35 bar 60 bar 80 bar Power assistance too low
Faulty control valve or
hydraulic piston
40 bar 35 bar 60 bar 60 bar Power assistance too low
Worn pump
65 bar 65 bar 80 bar 80 bar Power assistance too high
Flow control valve stuck
closed/faulty
Key term
Noise and bleeding
Cavitation – the creation of
Noise from a hydraulic power-assisted steering system may be caused by: bubbles in a hydraulic fl uid.
∑ loose drive belt
∑air in the hydraulic system, known as cavitation
∑pump bearing wear.
If air has entered the system, it can be bled by topping up the fl uid
reservoir with the correct grade of power steering fl uid and turning the
steering from lock to lock with the engine running. This will help fl uid
to fully circulate through the steering system and air to escape once it
has reached the reservoir. Time
Speed sensitive solenoid diagnosis Figure 2.44 Analogue speed signal
To diagnose the correct operation of the speed sensitive system, you
need to connect an oscilloscope to the speed sensor input at the power
steering ECU. (You can fi nd out how to connect and use an oscilloscope
in Chapter 4, pages 184–185.). Key term features defne
With the vehicle in motion, you should see a wave form with a frequency
diffcult and important
proportional to vehicle speed on the screen of the oscilloscope. This
signal may be analogue (see Figure 2.44) or digital (see Figure 2.45). If concepts to aid understanding
you don’t see this wave form, check the sensor and wiring.
If the input to the ECU is correct, you should then connect the throughout the book.
oscilloscope to the output for the power steering solenoid. At slow
speed, you should see a duty cycle or pulse width modulation (PWM) Time
on the screen of the oscilloscope that reduces as vehicle speed increases. Figure 2.45 Digital speed signal
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Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
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Candidate Handbook
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Volts
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Level 3L eLvigehl t2 VNeVhQic/lSeV TQe cDhipnlolmogay Brickwork 3rd edition
If the output signal is correct, then you should check the wiring and
solenoid for correct function and operation.
If the input to the electronic control unit is correct but the output is
50% Duty cycle missing or incorrect, you should suspect a fault with the ECU.
75% 75%
Electro-hydraulic power-assisted steering
75%2 D5%uty cycle 25% An alternative to the engine-driven hydraulic pump used in power-assisted
steering is for the pump to be driven using an electric motor. The electric
Figure 2.46 Duty cycle wave form motor, pump and fl uid reservoir can then be mounted in a position away
from the engine and activated when required. Sensors mounted on the
steering column are able to measure the amount of turning effort applied
to the steering system by the driver and send this information along with
a signal from the vehicle’s speed sensor to the steering electronic control
unit (ECU). The ECU is then able to operate the electric motor to turn
the pump and supply a pressure to the piston in the steering rack which is
proportional to vehicle speed and the steering effort applied.
The advantages of this type of system are:
∑Fewer loads are placed on the engine during operation, so fuel
economy and engine emissions are improved.
∑The pump and reservoir can now be mounted anywhere away from
the engine, which increases the scope for vehicle design.
∑If the engine stalls/cuts out, power assistance can be maintained.
∑The pump can be controlled by a switch to provide even greater
assistance when parking.
High-quality illustrations Pinion
Electro hydraFuluicid p ruemseprvoir
throughout help learners Valve rotor
visualise technical concepts Valve sleeve
and automotive systems. Feed oil radial groove
Power cylinder left Piston
Rack housing
Power cylinder right Rack Pinion Tie rod
Clear and concise
Figure 2.47 Electro-hydraulic power steering
explanation of technical
Electronic power-assisted steering (EPS) level 3 concepts assist
Many modern vehicles use electric motors to drive steering mechanisms
and provide power assistance instead of hydraulics. A reversible direct understanding.
current electric motor can be connected to the steering rack or column
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Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
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2 Diagnosis & rectifi cation of light vehicle chassis system faults
depending on manufacturer design. As the driver Steering wheel
applies effort at the steering wheel, movement and
turning effort are registered by a torque sensor
mounted on the steering column. The information Steering column
provided by this sensor, as well as other inputs
such as vehicle speed are then sent to the steering Track rod ends
electronic control unit (ECU). The ECU is then Universal joint Electric motor
able to operate the electric motor in the desired Pinion Pinion housing
direction with a force controlled by duty cycle Rubber gaiters
with a force that is proportional to vehicle speed
and steering effort applied.
The advantages of this system are: Steering rack Track rods Ball joints
∑The motor is only operated when the steering Figure 2.48 Electronic power-assisted steering
is turned – this reduces loads, improves fuel
economy and reduces engine emissions.
∑The motor and control system is very compact and can be used
unobtrusively, even on small cars.
∑Assistance can be easily varied to provide greater help when parking.
∑Less maintenance is needed as there is no fl uid system or leaks.
∑If combined with a vehicle radar system, it can be used to provide a
self-parking function.
To diagnose faults with electronic power-assisted steering systems, you
can often use a scan tool to retrieve diagnostic trouble codes (DTCs),
NEW TECH Action
Self-parking cars Investigate vehicles in your
Parallel parking is a slow speed manoeuvre that many drivers fi nd diffi cult. As a response workshop and state if they use:
to consumer demand, car manufacturers are starting to design and sell self-parking cars. • hydraulic power-assisted
Advantages of self-parking cars include: steering
• Choosing a parking space is not restricted by the driver’s skill at parallel parking. • electro-hydraulic power-
• A self-parking car can often f t into smaller spaces than most drivers can manage on assisted steering
their own, which allows the same number of cars to take up fewer spaces. • electronic power-assisted
• Parking takes less time, which helps to keep traff c moving. steering.
• Minor damage created by parking is reduced.
Many systems operate with the driver controlling vehicle speed and direction with the
normal driving controls. They have sensors distributed around the front and rear bumpers of Action features provide tasks
the car, which act as both transmitters and receivers. These sensors send out signals, which
bounce off objects around the car and ref ect back to them. The car’s ECU then uses the to contextualise what has been
amount of time that it takes those signals to return to calculate the location of the objects.
The electronic power-assisted steering then manoeuvres the car into the parking space. learnt and demonstrate
Manufacturers are now designing vehicles that are completely autonomous and wil understanding of concepts.
control the drive as well as the steering. This means that the driver simply has to select
an appropriate parking spot and position the vehicle close to the space. Having pressed a
button, the car can then park completely by itself.
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Sample taken from Level 3 Light Vehicle Technology Candidate Handbook.
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Candidate Handbook
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training resourCe disk
l Save valuable time with an array of tools to help plan
effectively, including suggested schemes of work, lesson plans
and PowerPoints.
l Matched to the Candidate Handbook so you can teach level 3
diagnostic skills and knowledge in an engaging and interactive
way that maximises success.
l Customise your training - all printable materials are editable,
training resourCe disk
so you can ensure the materials are right for your learners.
8
training resourCe disk

Chapter 6 Identifying and agreeing motor vehicle customer service needs

Assignment 1 Customer care

Candidate name Date
Assignment brief:
1 Create a script that could be used to greet customers face to face when they arrive
at the garage for the first time and which finds out their service or repair needs.
2 Create a script that could be used to greet customers over the phone when they
contact the garage for the first time and which finds out their service or repair needs.
Attach your scripts to this cover sheet.
3 Conduct a role-play activity with another learner where your script can be
assessed by one of your peers and constructive feedback given.
Peer assessment and feedback
Peer assessor Date
General comment about the assignment:
Assessment criteria
Did the candidate? Yes/No
Use customer service methods appropriate for a face-to-face
greeting.
Use customer service methods appropriate for a telephone greeting.
Fully establish the service or repair needs during the role-play
activity.
Assessment for learning
Peer assessor Please give a brief description of how this assignment could have been
improved (this could be about technical content or the general approach to the assignment
submission).
Assignments allow learners to put
Customer service skills can be what they have learnt into practice
vital in a garage setting and our and apply their knowledge at the end
customer care chapter aims to of each chapter.
equip learners with th ese skills.
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© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free.
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
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training resourCe disk
draft
training resourCe disk

Chapter 6 Identifying and agreeing motor vehicle customer service needs

Assignment answers

Assignment introduction
The assignments provided in this chapter are designed to offer tasks which support
and extend classroom learning.
Every opportunity should be taken to allow learners to peer and self-assess the
work, promoting assessment for learning and reducing tutor marking, while allowing
for formative assessment to take place.
Assignment 1 Customer care
Learners produce/create a customer greeting script and then undertake a role-play
activity to judge its effectiveness.
Peers check that the assignment/role-play contains the following information:
1 Customer service methods appropriate to a face-to-face greeting
2 Customer service methods appropriate to a telephone greeting
3 Fully establish the service or repair needs
Peers give constructive feedback on technical content, spelling, punctuation,
grammar and layout.
Assignment 2 Manufacturer data
Learners research manufacturer communication and feedback by using email
requests for information.
Learners produce individual answers.
Learners self-assess the effectiveness of the activity and describe how different
forms of written communication could be used in a business situation.
Assignment 3 Common faults
Learners research vehicle faults using the Internet and diagnostic questioning sheets
designed in Chapters 2, 3, 4 or 5.
Learners produce individual answers.
Peer/group assessors check the effectiveness of the activity.
Each assignment comes with
Assignment 4 Garage services
answers so you can make sure
Learners research local garage products and services and complete a table for three
different garages. your learners are on track.
Learners produce individual answers.
Learners self-assess the effectiveness of the activity.

1
© Pearson Education Ltd 2012. Copying permitted for purchasing institution only. This material is not copyright free.
Sample taken from Level 3 Light Vehicle Technology Training Resource Disk.
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training resourCe disk
draft