Diagnose and rectify heavy goods and public service vehicle transmission and driveline system faults

This standard is about diagnosing and rectifying faults occurring within heavy goods and public service vehicle gearboxes, axles and bearings, driveline, final drive and clutches, including those which incorporate electric and hybrid driveline systems.

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 diagnostic information in a systematic way relevant to the diagnostic methods used

P7 collect sufficient diagnostic information to enable an accurate diagnosis of transmission and driveline system faults

P8 identify and record any system deviation from acceptable limits 

P9 ensure your assessment of dismantled sub-assemblies, units and components identifies their condition and suitability for repair or replacement

P10 promptly inform the relevant person(s) where repairs are uneconomic or unsatisfactory to perform

P11 use the equipment required, correctly and safely throughout all rectification activities

P12 carry out all rectification activities following:

P12.1 manufacturer’s instructions

P12.2 industry recognised repair methods

P12.3 your workplace procedures

P12.4 health, safety and environmental requirements

P13 work in a way which minimises the risk of :

P13.1 damage to other vehicle systems, units and components

P13.2 contact with leakages and hazardous substances

P13.3 damage to your working environment

P13.4 injury to self and others

P14 ensure all repaired and replaced units and components conform to the vehicle operating specification and any legal requirements

P15 adjust units and components correctly to ensure that they operate to meet system requirements, when necessary

P16 promptly record and report any additional faults you notice during the course of work 

P17 use testing methods which are suitable for assessing the performance of the system rectified

P18 ensure the transmission and driveline system rectified performs to the vehicle operating specification and any legal requirements prior to return to the customer

P19 ensure your records are accurate, complete and promptly passed to the relevant person(s)in the format required

P20 complete all system diagnostic activities within the agreed timescale 

P21 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 legal requirements relating to the vehicle (including road safety requirements)

K3 the implications on an Operators Licence of not carrying out repairs and inspections correctly

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 documenting diagnostic and rectification information

K6 the importance of working to agreed timescales and keeping others informed of progress

K7 the relationship between time, costs and productivity

K8 the importance of promptly reporting anticipated delays to the relevant person(s)

Electrical and electronic principles

K9 the hazards associated with working on or near high voltage electrical vehicle components

K10 electrical and electronic principles associated with heavy goods and public service vehicle transmission and driveline systems, including types of sensors and actuators, their application and operation

K11 how heavy goods and public service vehicle electrical and electronic transmission and driveline 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 and systems within heavy goods and public service vehicle transmission and driveline systems, including electric and hybrid driveline systems

K13 electrical symbols, units and terms

K14 electrical safety procedures 

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Use of diagnostic and rectification equipment

K15 how to prepare and check diagnostic testing *equipment

K16 how to use diagnostic and rectification equipment for heavy goods and public service vehicle transmission and driveline mechanical, electrical, pneumatic, hydraulic and fluid systems, specialist repair tools and general workshop equipment

Transmission and driveline faults, their diagnosis and correction

K17 how heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems are constructed, dismantled, reassembled and operate

K18 the types and causes of heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid system unit and component faults and failures

K19 heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid unit and component replacement procedures, the circumstances which will necessitate replacement and other possible courses of action

K20 how to find, interpret and use sources of information on heavy goods and public service vehicle transmission and driveline electrical and electronic operating specifications, diagnostic test procedures, repair procedures and legal requirements

K21 vehicle operating specifications for limits, fits and tolerances relating to transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems for the types of vehicle on which you work

K22 how to select the most appropriate diagnostic testing method for the symptoms presented

K23 how to carry out systematic diagnostic testing of heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems using a prescribed process or format

K24 how to assess the condition evident within heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid units and components

K25 how to interpret test results and vehicle data in order to identify the location and cause of vehicle system faults

K26 how to carry out rectification activities in order to correct faults in heavy goods and public service vehicle transmission and driveline mechanical, electrical, electronic, pneumatic, hydraulic and fluid systems

K27 the relationship between test methodology and the faults repaired – the use of appropriate testing methods

K28 how to make cost effective recommendations for rectification 

K29 the importance of inspecting the vehicle following any repairs

1.1. gearbox and power take off
1.2. axles and bearings
1.3. driveline shafts
1.4. clutch
1.5. final drive
1.6. electric and hybrid driveline systems

2. Diagnostic methods are:

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

3. Equipment is:

3.1. diagnostic and rectification equipment for transmission and driveline mechanical systems
3.2. diagnostic and rectification equipment for transmission and driveline electrical and electronic systems
3.3. diagnostic and rectification equipment for transmission and driveline hydraulic and fluid systems
3.4. diagnostic and rectification equipment for transmission and driveline pneumatic systems
3.5. specialist repair tools
3.6. general workshop equipment

4. Faults are:

4.1. mechanical
4.2. electrical and electronic
4.3. hydraulic and fluid
4.4. pneumatic