Diagnose and rectify heavy goods and public service vehicle chassis system faults

This standard is about diagnosing and rectifying faults occurring within heavy goods and public service vehicle steering and suspension systems, braking systems and other systems fitted to heavy goods and public service vehicle chassis.

P2.1 technical data

P2.2 diagnostic test procedures

P3 prepare the vehicle, vehicle systems and work area for safe working procedures as appropriate to the vehicle and environment 

P4 prepare, connect and check all the required equipment following manufacturers' instructions prior to use

P5 use diagnostic methods which are relevant to the symptoms presented

P6 collect sufficient diagnostic information in a systematic way to enable an accurate diagnosis of chassis system faults

P7 identify and record any system deviation from acceptable limits 

P8 ensure your assessment of dismantled sub-assemblies, units and components identifies their condition and suitability for repair or replacement

P9 promptly inform the relevant person(s) where repairs are uneconomic or unsatisfactory to perform

P10 use the equipment required, correctly and safely throughout all rectification activities

P11 carry out all rectification activities following:

P11.1 manufacturers' instructions

P11.2 industry recognised repair methods

P11.3 your workplace procedures

P11.4 health, safety and environmental requirements

P12 work in a way which minimises the risk of:

P12.1 damage to other vehicle systems, units and components

P12.2 contact with leakages and hazardous substances

P12.3 damage to your working environment

P12.4 injury to self and others

P13 ensure all repaired and replaced units and components conform to the vehicle operating specification and any legal requirements

P14 adjust units and components correctly to ensure that they operate to meet system requirements, when necessary

P15 promptly record and report any additional faults you notice during the course of work 

P16 use testing methods which are suitable for assessing the performance of the system rectified

P17 ensure the rectified chassis system performs to the vehicle operating specification and any legal requirements prior to return to the customer/driver

P18 ensure your records are accurate, complete and passed to the relevant person(s) within the agreed timescales in the format required

P19 complete all system diagnostic activities within the agreed timescale

P20 promptly report any anticipated delays in completion to the relevant person(s) 

K1.1 health and safety

K1.2 the environment (including waste disposal)

K1.3 appropriate personal and vehicle protective equipment

K2 the implications on an Operators Licence of not carrying out repairs and inspections correctly

K3 legal requirements relating to the vehicle (including road safety requirements)

K4 your workplace procedures for

K4.1 recording diagnostic and rectification activities

K4.2 the referral of problems

K4.3 reporting delays to the completion of work

K5 the importance of working to industry recognised diagnostic and rectification procedures and processes and obtaining the correct information for diagnostic and rectification activities to proceed

K6 the importance of recording diagnostic and rectification information

K7 the importance of working to agreed timescales and keeping others informed of progress

K8 the relationship between time, costs and productivity

K9 the importance of promptly reporting anticipated delays to the relevant person(s) 

Electrical and electronic principles

K10 electrical and electronic principles associated with chassis systems, including types of sensors and actuators, their application and operation

K11 how electrical and electronic chassis systems operate, including electrical component function, electrical inputs, outputs, voltages and oscilloscope patterns, digital and fibre optics principles

K12 the interaction between electrical, electronic and mechanical components within vehicle chassis systems

K13 electrical symbols, units and terms

K14 the hazards associated with working on or near high voltage electrical vehicle components

Use of diagnostic and rectification equipment

K15 how to prepare and check the accuracy of diagnostic testing equipment

K16 how to use diagnostic and rectification equipment for chassis mechanical, electrical, pneumatic, hydraulic and fluid systems, specialist repair tools and general workshop equipment

Chassis faults, their diagnosis and rectification

K17 how chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems are constructed, dismantled, reassembled and operate

K18 how chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems are dismantled, reassembled and adjusted to manufacturers’ specifications

K19 the types and causes of chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid system unit and component faults and failures

K20 chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid unit and component replacement procedures, the circumstances which will necessitate replacement and other possible courses of action

K21 how to find, interpret and use sources of information on chassis electrical and electronic operating specifications, diagnostic test procedures, repair procedures and legal requirements

K22 vehicle operating specifications for limits, fits and tolerances relating to chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems for the types of vehicle on which you work

K23 how to select the most appropriate diagnostic testing method for the symptoms presented

K24 how to carry out systematic diagnostic testing of chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems using a prescribed process or format

K25 how to assess the condition evident within chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid units and components 

K26 how to interpret test results and vehicle data in order to identify the location and cause of vehicle system faults

K27 how to carry out rectification activities in order to correct faults in the chassis mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems

K28 the relationship between test methodology and the faults repaired – the use of appropriate testing methods

K29 how to make cost effective recommendations for rectification 

K30 the importance of inspecting the vehicle following any repairs

1.1. steering
1.2. suspension
1.3. braking

2. Diagnostic methods are:

2.1. sensory
2.2. measurement
2.3. functional testing
2.4. electrical and electronic systems testing

3. Diagnostic testing is defined as:

3.1. verify the fault
3.2. collect further information
3.3. evaluate the evidence
3.4. carry out further tests in a logical sequence
3.5. rectify the problem
3.6. check all systems

4. Equipment is:

4.1. diagnostic and rectification equipment for chassis mechanical systems
4.2. diagnostic and rectification equipment for chassis electrical and electronic systems
4.3. diagnostic and rectification equipment for chassis hydraulic and fluid systems
4.4. diagnostic and rectification equipment for chassis pneumatic systems
4.5. specialist repair tools
4.6. general workshop equipment

5. Faults are:

5.1. mechanical
5.2. electrical and electronic
5.3. hydraulic and fluid
5.4. pneumatic