Fitting ancillary units to commercial and passenger carrying vehicles
Overview
This standard identifies the competences you need to fit ancillary units to commercial and passenger carrying vehicles, in accordance with approved procedures. You will be required to fit a range of different ancillary units, such as rear axle/brake sub-assemblies, power unit sub-assemblies, fifth wheel units, hydraulic hoist/lifting equipment, tail lift or fork truck units, power winches, stabilising legs, refrigeration units, heating and ventilation units, hydraulic rams, pneumatic components, generators, pumps, power take-off units, domestic equipment and lighting units, to the vehicle by using a variety of assembly methods and techniques. You will also be expected to use a range of tools and specialist equipment associated with the fitting and assembly methods, and to check that the fitted assembly has been completed to the level of accuracy and quality required by the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the fitting and assembly activities undertaken, and to report any problems with the process that you cannot resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying procedures appropriate to the fitting of ancillary units to vehicles. You will understand the ancillary units being fitted to the vehicle, and their application, together with the fitting and assembly methods and techniques used and associated tools and equipment, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the fitting and assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble and fit the components in their correct positions
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational policy
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of drawing, job instructions and specifications that are used during the fitting and assembly of ancillary units and associated components to the vehicle, and how to interpret them correctly
- how to identify the components to be used; component identification systems (codes and component orientation indicators)
- the fitting and assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the ancillary units and associated components are to be aligned and positioned prior to securing, and the tools and equipment that are used
- the methods and techniques for the various joining methods to be used
- how to apply sealants and adhesives within the fitting and assembly activities, and the precautions to be taken when working with them
- how to set and operate the relevant welding equipment safely and correctly
- the operational functions of the various ancillary units and associated components you are fitting
- the use of torque wrenches, and the importance of ensuring fasteners are adjusted to the required settings
- the consumables, tools and equipment that are used for the fitting and assembly of ancillary units and associated components to the vehicle
- the importance of using the specified ancillary unit and associated components, and why you must not use substitutes
- how to deal with assemblies and that are incorrectly fitted and assembled, damaged or that have other faults
- quality control procedures to be followed during fitting and assembly
- how to conduct checks to ensure the accuracy and quality of the fitted assembly
- the importance of completing the all relevant documentation correctly
- recognising defects (such as incorrect assembly, ineffective fasteners, damage)
- the importance of ensuring that the complete fitted assembly is free from left-over items and foreign objects
- the methods and equipment used to transport, handle and lift the ancillary units and components into position, and how to check that any equipment required is within its current certification dates
- preparations to be undertaken on the ancillary units and associated components prior to fitting into the vehicle
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition.
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the problems with the fitting and assembly operations, and the importance of informing the appropriate people of non- conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the fitting/assembly activities:
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, quality control documentation) use the correct assembly drawings, specifications or job instructions
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other safety regulations and procedures to realise a safe system of work
- check that all cables, extension leads or air supply hoses are in a safe, tested and serviceable condition
- check that all tools and equipment to be used are within current calibration/certification dates
- ensure that sub-assemblies and components used are free from damage, foreign objects, dirt or other contamination before assembling them
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- use safe and approved techniques to assemble the sub-assemblies and components to the vehicles
- return all tools and equipment to the correct location on completion of the assembly activities
- leave the work area in a safe and appropriate condition on completion of the activities
Fit three of the following complete sub-assembly units to the vehicle:
- fifth wheel unit
- power winch
- stabilising legs
- power take-off units
- refrigeration unit
- generators
- pumps
- lighting units
- rear axle/brake sub-assembly unit
- hydraulic rams for tippers and demountables
- power unit sub-assembly
pneumatic equipment/components
hydraulic hoist/lifting equipment
- water storage units (fresh or waste)
- tail lift or fork truck unit
- domestic equipment (such as sinks, toilets, showers)
- heating/ventilation and air conditioning units
- access/regress ramp
- close circuit television (CCTV) recording equipment
- distance calibration equipment
- destination boards
- global positioning system (GPS) equipment
Fit sub-assemblies/components, using four of the following:
- mechanical fasteners
- sealants/bonding
- rivets
- welded fasteners
- welding
- drive/interference fits
- pins
- adhesives
- adhesive tapes
Fit sub-assemblies/components to vehicles, using three of the following devices:
- jigs
- power tools
- torque drivers
- lifting device
- fixtures
- power drivers
- alignment device
- hand tools
Fit sub-assemblies to the vehicle, using five of the following components:
- locators
- mounting brackets
- special connectors
- strengthening plates
- positional brackets
- control wires and rods
- cables and connectors
- spring/snap clips
- foam/padding
- pipes/hoses and connectors
- terminals
- adhesive/tape
Carry out the required quality checks, to include seven of the following:
- dimensions
- positional accuracy
- freedom from damage and foreign objects
- alignment
- torque loading of bolts
- component quality
- completeness
- component security
- function
Check that the ancillary units and their fitting, comply with one of the following quality and accuracy standards:
- legislation, industry standards, codes of practice and procedures specific system requirements
- customer standards and requirements
- company standards and procedures