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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
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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.
© Commonwealth of Australia 2011
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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.
© Commonwealth of Australia 2011
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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.
© Commonwealth of Australia 2011
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.
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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
© Commonwealth of Australia 2011
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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)
© Commonwealth of Australia 2011
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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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
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
Learner workbook pp. 30-33
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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
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
Learner workbook pp. 37-38
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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
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
Oral presentation Learners answer questions 1-4 Explain assessment requirements of
removing and replacing 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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
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
Oral presentation Learners answer questions 1-8 Explain assessment requirements of
removing and replacing water pump
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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
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
© Commonwealth of Australia 2011
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TOPIC INFORMATION METHODOLOGY RESOURCES
Glossary Learner workbook pp. 80-81
© Commonwealth of Australia 2011
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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.
© Commonwealth of Australia 2011
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ASSESSOR OBSERVATION CHECKLIST
Did the candidate’s overall performance meet the standard? Yes No
Feedback to candidate
General comments / Strengths / Improvements needed
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Candidate signature: __________________________________ Date: ____/____/20___
Assessor signature: __________________________________ Date: ____/____/20___
© Commonwealth of Australia 2011
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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?
© Commonwealth of Australia 2011
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ASSESSOR QUESTIONS
The candidate’s underpinning knowledge was: Satisfactory Not satisfactory
Feedback to candidate
General comments / Strengths / Improvements needed
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Candidate signature: __________________________________ Date: ____/____/20___
Assessor signature: __________________________________ Date: ____/____/20___
© Commonwealth of Australia 2011
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