Certificate in Land-based Service Engineering Levels 2 and 3 3942

Scheme handbook

City & Guilds is the UK’s leading provider of vocational qualifications, offering over 500 awards across a wide range of industries and progressing from entry level to the highest levels of professional achievement. With over 8500 centres in 100 countries, City & Guilds is recognised by employers worldwide for providing qualifications that offer proof of the skills they need to get the job done. The City & Guilds Group includes City & Guilds Pitman Qualifications, specialising in IT, office-based qualifications and English as a second language awards, and ILM (the Institute of Leadership & Management) providing management qualifications, learning materials and membership services. City & Guilds also manages the Process Technology Council Examinations on behalf of the Process Technology Council General information about City & Guilds is available on our website www.city-and-guilds.co.uk or from our Customer Relations team by phoning 020 7294 2800 or e-mailing enquiry@city-and-guilds.co.uk

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Contents Page

Levels 2 & 3 Certificates in Land-based Service Engineering 5 General information 7

General structure 7 Assessment and quality assurance 7 Course design 8 Centre and scheme approval 8

Registration and Certification 8 Verification of assignments 9 Health and safety 9 Guidance on assessment 11 Introduction 11 What is provided by City & Guilds 11 On line assessment requirements 12

GOLA registrations 12 What centres need to do 12 Assignments 12

Producing Centre Devised Assignments 13 Submitting Centre Devised Assignments 13 The Award 15 Relationship to Lantra standards 16 Test specifications 17

Key skills 18 Employment Rights and Responsibilities 19

The Units 20- 53 Unit 001 Land-based Service Engineers’ Workshop Practices Unit 002 Fabrication and Joining in the Land-based Sector Unit 003 Maintenance of Tractors and other Land-based Machinery Unit 004 Repair of Tractors and other Land-based Machinery Unit 005 Arc Welding Processes in the Land-based Sector

Appendix A Centre devised submission report form 54-55

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Levels 2 & 3 Certificates in Land-based Service Engineering The Level 2 Certificate in Land-based Service Engineering and the Level 3 Certificate in Land-based Service Engineering are aimed at candidates who • are following Lantra Modern Apprenticeship programmes • require evidence towards the underpinning knowledge of the related Lantra N/SVQ. • wish to achieve an alternative award to an NVQ • wish for career progression within the Land-based Service Engineering industry • wish to acquire a nationally recognised qualification in Land-based Service Engineering • wish to gain employment in the Land-based Service Engineering industry There is no prescribed recommended prior knowledge, attainment or experience needed to gain access to this qualification. However, it is recommended that potential candidates are initially assessed to determine whether or not they have an understanding of the uses and dangers of land-based machinery and their application within the industry and also to determine levels of literacy, numeracy, communication skills and sector understanding. Where a candidate does not possess this knowledge it is recommended that remedial action is taken before accepting them for this qualification. Both awards are designed to satisfy the underpinning knowledge requirements of the City & Guilds Levels 2 & 3 NVQs in Land-based Service Engineering (schemes 4024 & 4025) The nature of both the learning and assessment required for the qualification is such that candidates will need literacy and numeracy skills: i.e. the ability to read and interpret written tasks and to write answers in a legible and understandable form. Candidates will also need to be able to organise written information clearly and coherently, although they will not be assessed for spelling or grammatical accuracy unless this is part of the assessment criteria. Certificates are available in a range of vocational areas, please contact Customer Relations at City & Guilds for further information.

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Levels 2 & 3 Certificates in Land-based Service Engineering General information Both Awards have been developed by City & Guilds to support government initiatives towards the National Qualifications Framework. General structure Both Awards are made up of units expressed in a standard format. Each unit is preceded by details of the • structure of the unit • aims and general coverage of the unit • relationship of the unit to the appropriate N/SVQ/ National Occupational Standards • outcomes • assessment methods.

Assessment and quality assurance National standards and rigorous quality assurance are maintained by the use of City & Guilds set and marked written tests • The question papers are graded (Pass (60%), Credit (70%) and Distinction (80%)) and listed

on Certificates of Unit Credit. A pass is the achievement level required for the knowledge and understanding in an NVQ and generally represents the ability to follow instructions and procedures. Credit and Distinction represent increasing levels of ability and knowledge.

• Centre devised assignments, which must be developed in line with City & Guilds assignment templates and approved by City & Guilds prior to use. Monitoring of assignments will be undertaken by City & Guilds through the external verification system. The practical assignments are graded Pass or Fail. Certificates (for the full award) do not carry a grade. Quality assurance includes initial centre approval, scheme approval and the centre’s own procedures for monitoring quality. Details of City & Guilds’ criteria and procedures, including roles of centre staff can be found in Providing City & Guilds Qualifications – a guide to centre and scheme approval.

For candidates with particular requirements, centres should refer to City & Guilds policy document Access to assessment, candidates with particular requirements. External verifiers act on behalf of City & Guilds to ensure that national standards are maintained. Full details of their role can be found in Providing City & Guilds’ Qualifications - a guide to centre and scheme approval.

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Course Design Teacher/assessors should familiarise themselves with the structure and content of the award before designing an appropriate course; in particular they are advised to consider the knowledge and understanding requirements of relevant N/SVQs where applicable. City & Guilds does not itself provide courses of instruction or specify entry requirements. As long as the requirements for the award are met, tutors/assessors may design courses of study in any way that they feel best meets the needs and capabilities of the candidates. Units are broadly the same size and centres may deliver them in any order they wish. Centres may wish to introduce other topics as part of the programme which will not be assessed through the qualifications, eg to meet local needs.

It is recommended that centres cover the following in the delivery of the course, where appropriate • Key Skills (such as Communication, Application of Number, Information technology, Working

with others, Improving own learning and performance, Problem solving) • Health and safety considerations, in particular the need to impress to candidates that they

must preserve the health and safety of others as well as themselves • Spiritual, moral, social and cultural issues • Environmental education • European dimension. It is recommended that 200 hours should be allocated for the three units required for certification at level 2 and 300 hours should be allocated for the three units required for certifications at level 3. Centre and scheme approval Centres wishing to offer City & Guilds qualifications must gain approval. New centres must apply for centre and scheme approval. Existing City & Guilds centres will need to get specific scheme approval to run this Award. Full details of the process for both centre and scheme approval are given in Providing City & Guilds qualifications - a guide to centre and scheme approval which is available from City & Guilds’ regional offices.

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Registration and certification Candidates must be registered at the beginning of their course. Centres should submit registrations using Form S (Registration) or via the Walled Garden, under scheme 3942. When assignments have been successfully completed, candidate results should be submitted on Form S (Results submission). Centres should note that results must NOT be submitted to City & Guilds until the external verifier is satisfied that the required standard has been attained. Candidates achieving one or more assessment components will receive a Certificate of Unit Credit listing the assessment components achieved together with the grade (D, C or P). Candidates achieving the number and combination of assessment components required for the award will, in addition, be issued a Certificate. Certificates are not graded. City & Guilds reserves the right to suspend an approved centre, or withdraw its approval from an approved centre to conduct a particular City & Guilds scheme or particular City & Guilds schemes, for reasons of debt, malpractice or for any reason that maybe detrimental to the maintenance of authentic, reliable and valid qualifications or that may prejudice the name of City & Guilds. Full details on all the above procedures will be found in the Directory of Vocational Awards published annually by City & Guilds. This information also appears on City & Guilds Web site http://www.city-and-guilds.co.uk

Verification of assignments Although Certificates do not imply occupational competence, they have a very close relationship with NVQ programmes. It is for this reason that, when assignments are assessed, it is important that reference is made to N/SVQ assessment methodology. Certificate assessors/tutors will need to be familiar with the occupational standards for Land-based Service Engineering N/SVQs, because a similar system of internal verification is used. This means that the work of assessors involved in the qualification must be monitored by an Internal Verifier/quality coordinator, to ensure that they are applying the standards consistently throughout assessment activities. External verification An External Verifier will make an annual visit to the centre and their role includes the following: • ensuring that internal verifiers are undertaking their duties satisfactorily • monitoring internal quality assurance systems and sampling assessment activities, methods

and records • acting as a source of advice and support • promoting best practice • providing prompt, accurate and constructive feedback to all relevant parties on the operation

of centres’ assessment systems.

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Health and safety The requirement to follow safe working practices is an integral part of all City & Guilds qualifications and assessments, and it is the responsibility of centres to ensure that all relevant health and safety requirements are in place before candidates start practical assessments. Should a candidate fail to follow health and safety practice and procedures during an assessment (e.g. practical assessment, assignment) the test must be stopped and the candidate advised of the reasons why. The candidate should be informed that they have failed the assessment. Candidates may retake the assessment at a later date, no less than seven days after the failure Feedback Assessors must ensure that candidates understand why a particular grade has been given for the award. If a candidate’s work is selected for verification, samples of work must be available to the appointed external verifier.

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Levels 2 & 3 Certificate in Land-based Service Engineering Guidance notes on assessment

Introduction

The City & Guilds Level 2 Certificate in Land-based Service Engineering and the City & Guilds Level 3 Certificate in Land-based Service Engineering are designed to provide opportunities for candidates to gain accreditation for their individual level of understanding of the underpinning knowledge relevant to the appropriate related NVQ. To be awarded the full certificate for the City & Guilds Level 2 Certificate in Land-based Service Engineering will be required to achieve all of the following mandatory units: Unit 001 Land-based Service Engineers’ Workshop Practices Unit 002 Fabrication and Joining in the Land-based Sector Unit 003 Maintenance of Tractors and other Land-based Machinery To be awarded the full certificate for the City & Guilds Level 3 Certificate in Land-based Service Engineering candidates will be required to achieve all of the following mandatory units: Unit 001 Land-based Service Engineers’ Workshop Practices Unit 004 Repair of Tractors and other Land-based Machinery Unit 005 Arc Welding Processes in the Land-based Sector Note - Candidates who have achieved Unit 001 Land-based Service Engineers’ Workshop Practices within the Level 2 Certificate will be deemed to have achieved this unit for the Level 3 Certificate. What is provided by City & Guilds

City & Guilds will provide multiple-choice examinations for unit 1 and 2 and for unit 5. These tests will be available on-line through the City & Guilds GOLA system. Each test will compromise of multiple choice items in accordance with the test specifications provided. Assignment templates will be provided for Units 002, 003, 004 and 005. On Line assessment requirements The entire test will be conducted via the candidate’s VDU. All data relating to the assessment will be held by City & Guilds with results and performance feedback being delivered back to the approved centre. City & Guilds will continue to apply its rigorous quality control procedures to the production, editing, marking, moderating and revision of all questions whilst at the same time applying a robust security system to prevent assessments being accessed or drawn down by unauthorised persons or for purposes beyond those authorised.

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GOLA registration Centres are required to register as a GOLA centre before any tests can be scheduled. The form for this is available from the website www.city-and-guilds.co.uk/e-assessment

A centre only needs to register once for GOLA Further information There is a GOLA helpline number - centre enquiries and technical enquiries about GOLA can be directed to this number 0845 241 0070.Centres can also e-mail: gola@city-and-guilds.co.uk.

The following leaflets are available: A centre’s guide to global on-line assessment A centre’s guide to technical requirements for global on-line assessment A centre’s guide to administering global on-line assessment A learner’s guide to global on-line assessment. Centres looking for general information about GOLA or copies of the GOLA leaflets are advised to use the website www.city-and-guilds.co.uk/e-assessment.

What centres need to do Centres must have access to sufficient equipment in the college, training centre or workplace to ensure candidates have the opportunity to cover all of the practical activities. It is acceptable for centres to use specially designated areas within a centre for some of the units. It is recommended that the equipment, systems or machinery must be of an industrial standard and be capable of being used as far as is practical under normal working conditions. Assignments

Units 002, 003, 004 and 005 specify a number of practical activities. EACH of these units is therefore assessed by the use of assignments. The assignment should be produced by the centre in accordance with the template provided by City & Guilds. It will be made up of a number of practical tasks. The resultant level of candidate achievement will be graded. Candidates MUST pass all tasks within an assignment. Assignments will provide opportunities for candidates to be assessed for a sample range of the practical activities required for the unit. Assignments will usually consist of several tasks. The range of assignments developed by the centre for each unit should ensure that all the practical activities for all the outcomes are assessed as the centre uses a range of assignments over a period of time. City & Guilds will provide assignment templates from which centres should produce the assignments for the units contained in this award. Centres are required to use the templates provided by City & Guilds. City & Guilds centre devised team must approve all assignments prior to use by the centre.

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Producing Centre Devised Assignments The centre devised assignments must be made up of the following sections: 1 Assessor’s Guidance Notes This section is intended for use by the assessor only. It should contain a health and safety statement the location of where the assignment should be taken the requirements for tools, equipment, materials and data notes on the content of the assignment to include any preparatory work required by the assessor/centre details of evidence and recording requirements time consideration. Any new assignments set must have the same time allocated to the completion of the assignment as set in the guidance note in the assignment template. 2 Candidate’s Instructions The candidate’s instructions should contain: • general advice to candidates about the need to understand the assignment before starting

work and the need to seek guidance if clarification is required guidance on the time limits • the importance of health and safety • an assignment brief which sets the scene or a scenario to contextualise the task(s) • clearly defined tasks covering a range of practical activities – an outline of each task should

be provided rather than a series of marking checklists • recording/report sheets for recording the progress of the activity notes which refer to how the

evidence they produce should be stored and labelled. Submitting Centre Devised Assignments All assignments must be approved for use by City & Guilds. Each assignment should be submitted with a copy of the Centre-devised assignment submission report. Centres must submit all centre devised assignments to Centre Devised Unit, City & Guilds, 1 Giltspur Street, London, EC1A 9DD Six weeks before they intend to use the assignment if submitted electronically to the following email address: centredevised@city-and-guilds.co.uk

Eight weeks before they intend to use the assignment if a paper based submission is made (three copies must be provided.) A copy of the Centre-devised assignment submission report is contained at the back of this handbook and should be submitted with the assignment.

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Levels 2 & 3 Certificates in Land-based Service Engineering

The Award For the award of a Level 2 certificate, candidates must successfully complete the assessments for Units 1, 2 and 3. For the award of a Level 3 certificate, candidates must successfully complete the assessments for Units 1, 4 and 5. Units Assessment components required

Unit 1 Land-based Service Engineers’ Workshop Practices 3942-02-001 Written-multiple choice

3942-02-002 Written-multiple choiceUnit 2 Fabrication and Joining in the

Land-based Sector 3942-02-012 Practical assignment

Unit 3 Maintenance of Tractors and other Land-based Machinery 3942-02-003 Practical assignment

Unit 4 Repair of Tractors and other Land-based Machinery 3942-03-004 Practical assignment

3942-03-005 Written-multiple choiceUnit 5 Arc Welding Processes in the

Land-based Sector 3942-03-015 Practical assignment

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Relationship to Lantra Land-based Service Engineering National Occupational Standards Unit Number/Title Related Lantra Unit(s) 001 Land-based Service Engineers’ Workshop Practices

1 – Contribute to health and safety 2 – Move loads 6 – Maintain the work area 9 – Maintain health and safety in the work environment

002 Fabrication and Joining in the Land-based Sector

3 – Shape components using hand tools 4 – Repair components by soldering and welding

003 Maintenance of Tractors and other Land-based Machinery

7 – Remove and replace components in tractors and machinery

8 – Maintain the condition of tractors and machinery 004 Repair of Tractors and other Land-based Machinery

10 – Establish and meet customers’ technical requirements for tractors and machinery 11 – Diagnose faults in tractors and machinery 12 – Dismantle, assemble and repair components in tractors and machinery 13 – Conduct testing of tractors and machinery following repair

005 Arc Welding Processes in the Land-based Sector

15 – Repair and modify components by welding

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Test Specification The knowledge requirements will be assessed by a multiple choice question paper for each of the following units: Component 001: Land-based Service Engineers’ Working Practices Test duration 45 minutes Total no of questions: 30

Unit Outcome

No of questions

1 Contribute to good housekeeping, repair and maintenance of hand tools an equipment

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2 Establish, maintain and strengthen working relationships and evaluate and develop own practice

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3 Apply safe working practices and procedures 6 4 Comply with statutory regulations and organizational

requirements 5

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5 Identify and follow accident and emergency procedures 5

Component 002 : Fabrication and Joining in the Land-based Sector Test duration 45 minutes Total no of questions: 30

Unit Outcome

No of questions

1 Use and care of hand tools 8 2 Welding using the manual metal arc (MMA) process 5 3 Welding using the metal inert gas (MIG) process 6 4 Welding using the oxy-acetylene gas process 5

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5 Produce soldered joints 6

Component 005: Arc Welding Processes in the Land-based Sector Test duration 1 hour 10 minutes Total no of questions: 45

Unit Outcome

No of questions

1 Prepare the equipment for manual metal arc (MMA) welding 7 2 Prepare the equipment for metal inert gas (MIG) welding 9 3 Prepare the equipment for tungsten gas (TIG) welding 8 4 Produce welded joints that conform to specification 21

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Level 2 Certificate in Land-based Service Engineering (3942-02) Level 3 Certificate in Land-based Service Engineering (3942-03) Identification of Key Skills summary relationship table Unit No and Title Communication Application

of Number Information Technology

1. Land-based Service Engineer’s Workshop Practices

C1.2 N1.1

2. Fabrication and Joining

3. Maintenance of Machinery

C1.2, C2.2 N1.1, N1.2 IT1.1

4. Repair Tractors and Machinery

C1.2, C2.2 N1.1, N1.2

5. Arc Welding Processes

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Level 3 Certificate in Land-based Service Engineering (3942-03) Employment Rights and Responsibilities matrix ERR Scheme handbook reference Employment law Statutory rights Unit1 Procedures and documentation Unit1 Sources of information and advice Unit1 Organisation and representation Organisation of the industry and how the job fits in

Unit1

Jobs, roles and careers Unit1 Representation in the industry Unit1 Sources of information and advice Unit1 Industry issues Principles and codes of practice Unit1 Issues of public concern Unit1

Identification of opportunities for evidence generation of Moral, Ethical, Spiritual, European Dimension, Environmental Education and Health and Safety Units Spiritual, Moral,

Ethical, Social and Cultural

Environmental Health and Safety

European Development

1 X X X X2 X X3 X X4 X X5 X X

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Unit 1 Land-based Service Engineers Working Practices

Rationale This unit is concerned with developing awareness of the skills associated with safety, good housekeeping and maintenance, developing personal relationships and taking some responsibility for others, which are essential to function effectively in the working environment. It covers general health and safety, conduct, interaction with colleagues and supervisors, communications, observation, listening skills and working effectively as a member of a team. This unit covers five performance outcomes. The candidate will be able to: 1. Contribute to good housekeeping, repair and maintenance of hand tools and equipment 2. Establish, maintain and strengthen working relationships and evaluate and develop own

practice 3. Apply safe working practices and procedures 4. Comply with statutory regulations and organisational requirements 5. Identify and follow accident and emergency procedures

Connection with other awards

The unit relates to the Lantra Land-based Service Engineering National Occupational Standards • Lantra LBSE 1.1 Identify and deal with hazards in the work area • Lantra LBSE 1.2 Deal with emergencies in the work area • Lantra LBSE 2.1 Prepare loads for moving • Lantra LBSE 2.2 Move loads • Lantra LBSE 6.1 Prepare work areas and materials • Lantra LBSE 6.2 Reinstate the work areas after engineering activities • Lantra LBSE 9.1 Minimise risks to life, property and the environment • Lantra LBSE 9.2 Deal with emergencies in the work environment

Assessment The outcomes from this unit will be assessed using evidence from:

1. Written tests The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice test covering the five outcomes.

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Outcome 1: Contribute to good housekeeping, repair and maintenance of hand tools and equipment Underpinning Knowledge The candidate will be able to 1. describe the scope of the job responsibilities for the use and maintenance of hand tools, equipment and work areas 2. describe the routine checks on the following types of tools and equipment a) hand b) electrical c) mechanical

d) pneumatic e) hydraulic 3. identify, select and check personal protective equipment (PPE) and respiratory protective equipment (RPE) a) overalls and safety helmets b) safety hand and footwear c) eye, face and ear protection d) barrier cream and cleansing soaps 4. describe the methods of maintaining and repairing hand tools and equipment

a) replacing damaged electrical plugs b) sharpening chisels and rectifying mushroomed heads c) sharpening centre punches d) tightening loose hammer and mallet heads e) cleaning files and tightening handles f) tightening leaking connections on pressurised workshop equipment g) draining compressors and water taps

5. summarise the health and safety consequences of inappropriate conduct or behaviour in the workplace 6. describe the types and meaning of warning signs in the workplace, both mandatory and informative 7. identify reference books, charts and tables to assist in problem solving 8. understand the importance of disposing of waster materials BS14001

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Outcome 2: Establish, maintain and strengthen working relationships and evaluate and develop own performance Underpinning Knowledge The candidate will be able to 1. describe the roles and responsibilities of people in the workplace 2. describe the main objectives and current regulations in the workplace a) Health and Safety at Work Act (1974) b) Employment Relations Act (1996) c) Disability Discrimination Act (1995) d) Sex Discrimination Act (1975) e) equal opportunities legislation f) Minimum Wage Legislation (1998) 3. describe the communication systems used in the workplace a) verbal b) written c) drawings d) electronic 4. describe how to seek assistance when needing clarification of instructions 5. describe how and when to approach a supervisor, trainer or colleague when experiencing difficulties with a task 6. describe the importance of honouring commitments to colleagues 7. describe the employers’ expectations with regards to conduct and manners when dealing with particular groups or situations a) supervisors, colleagues, visitors and customers b) receiving instructions 8. understand the operational constraints which may affect interaction with colleagues 9. understand the methods of self assessment a) describe own practice against goals and targets b) identify and select valid evidence for self assessment c) interpret evidence with the support of others d) assess impact of own behaviour and values e) evaluate and apply results of own performance evidence to reflect on own practice and professional issues f) explain how to accept criticism in a positive manner and assess it for validity and importance g) explain how to revise own goals and targets following review of all performance evidence 10. identify self assessment needs

a) set and prioritise clear and realistic goals for own development b) assess goals and targets based on understanding of own i) current competence ii) current and anticipated future demands of the job iii) aspirations iv) overall organisational needs

c) ensure own goals and targets take account of training and development and related areas d) identify ways of achieving goals and targets e) regularly reviewing Personal Action Plan

f) ensure trying various ways of developing own practice does not cause problems for others g) ensure developments to own practice are evaluated and used for continued self-development 11. describe the role of Health and Safety Representatives and Representatives of Employee Safety

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12. understand who to approach when seeking guidance, assistance of help a) colleagues b) supervisors c) trainers 13. describe the manner in which to approach colleagues, supervisors or trainers when seeking help or assistance a) politeness b) patience c) confidence 14. describe the circumstances when it will be essential to make an assertive approach or request

a) accident risk b) unacceptable behaviour c) ignored requests

15. describe how to react when receiving unwelcome requests, warnings or reprimands especially if they are delivered impatiently, embarrassingly or aggressively 16. describe how to conduct self assessment checks 17. describe the relevance and organisational purposes of learning contracts 18. understand the need for continuous assessment and/or phased written or practical tests to monitor achievement

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Outcome 3: Apply safe working practices and procedures Underpinning Knowledge The candidate will be able to 1. describe variations in dress codes and Personal Protective Equipment (PPE) and Respiratory Protective Equipment (RPE) to suit differing situations a) materials handling b) rotating machinery c) welding d) abrasive welding 2. describe the range of specialist PPE available to suit the working environments 3. explain the procedures for obtaining and returning specialist PPE after use 4. state that parasites, infections and diseases can be transmitted by the shared use of certain items of PPE a) dust masks b) gloves c) ear plugs/defenders d) eye protection 5. state the importance of maintaining overalls in good condition by regular washing/cleaning and repair 6. explain that compressed gases must not be used to remove dust from overalls/clothing 7. describe how to lift and carry loads without risking damage or injury to self or others 8. describe how to use manual aids to move loads a) pinch bars b) roller skates c) pallet trucks 9. describe the advantages, limitations and applications of transporting materials by use of a) pallet trucks b) fork lift trucks c) telescopic handlers 10. describe the range and application of lifting aids/accessories a) block and tackle b) rope, wire and chain slings

c) lifting clamps d) eyebolts and shackles e) vehicle lifts/hoists and wheel fitment rigs f) hydraulic jacks, axle stands and chocks

11. explain the dangers of faulty or misused lifting aids and techniques a) knots in slings b) frayed rope slings c) loads with sharp corners d) loose and swinging loads 12. state good housekeeping procedures and reasons for maintaining lifting equipment and ancillaries 13. state the precautions taken in relation to a) batteries b) braking systems c) electrical/electronic circuits d) wheels and tyres e) fuel systems i) petrol ii) diesel f) cooling systems g) air/gas exhaust systems h) steering and suspension systems

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i) air conditioning systems j) engine and transmission systems

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Outcome 4: Comply with statutory regulations and organisational requirements

Underpinning Knowledge The candidate will be able to 1. describe the main objectives of the statutory health and safety regulations relating to a working environment a) noise levels b) ventilation and fume extraction

c) lighting d) housekeeping e) machine guarding f) manual handling g) cranes and lifting h) Personal and Respiratory Protective Equipment (PPE and RPE) i) warning and advisory signs

2. explain the implication of COSHH regulations (1999) 3. describe basic safety and accident prevention measures relating to

a) chemical spillages b) welding radiation c) stacking and moving materials d) handling and storing gas cylinders e) flammable materials f) portable hand tools g) corrosive and cleaning liquids h) solvents i) fuels and lubricants j) operation of i) vehicle lifts ii) hoists iii) hydraulic lifting devices

4. state the types of emergency stop systems generally fitted to machinery relating to a) stop buttons b) foot pedals 5. identify, plan and allocate work methods to optimise use of resources

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Outcome 5: Identify and follow accident and emergency procedures Underpinning Knowledge The candidate will be able to 1. state the location of first aid facilities 2. describe situations which could lead to accidents a) working above ground, in pits and on site b) electrical supply and equipment

c) rotating or reciprocating machinery d) welding e) moving and storing machinery f) unsafe loads g) faulty tools and equipment

3. state the procedures to follow in the event of an accident 4. state accident reporting procedures 5. state the basic action to be taken in the case of electric shock

a) isolate b) removal from live source

6. state the dangers of inappropriate behaviour in the workplace 7. state the location of emergency power stops, alarms and fire fighting equipment 8. list the types and applications of fire extinguishers a) water b) powder c) foam d) CO² 9. state the evacuation procedures, escape routes and assembly points 10. explain how to recognise situations which may not comply with health and safety and other relevant legislation and guidelines 11. describe the purpose of a risk assessment procedure 12. assess work methods and procedures to ensure they are a) suitable for the situation b) technically feasible c) compatible with health and safety and other legislation and guidelines

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Unit 2 Fabrication and Joining in the Land-based Sector

Rationale This unit is concerned with the technology and practices involved in the application of fabrication and joining techniques, including welding. The unit is divided into five processes: fabrication, manual metal arc (MMA), metal inert gas (MIG), oxy-acetylene gas welding and soldering together with an understanding of the practicalities of joining fabrications. This unit covers five performance outcomes. The candidate will be able to: 1 Safe use and care of hand tools 2 Welding using the manual metal arc (MMA) process 3 Welding using the metal inert gas (MIG) process 4 Welding using the oxy-acetylene gas process 5 Process soldered joints Connection with other awards The unit relates to the Lantra Land-based Service Engineering National Occupational Standards

• Lantra LBSE 3.1 Shape components by material removal using hand tools • Lantra LBSE 3.2 Shape components by manually applied pressure • Lantra LBSE 4.1 Repair components by soldering and welding

Assessment The outcomes from this unit will be assessed using evidence from: Practical activities The assessment will be by means of a centre set practical assignment Written tests The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice test covering the five outcomes.

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Outcome 1: Safe use and care of hand tools Practical Activities The candidate will be able to 1. select the most effective process for a given application and quality specification 2. use hand tools and equipment to produce fabrications to meet quality specification Underpinning Knowledge The candidate will be able to 1. identify the features of engineering drawings a) free hand sketching i) pictorial perspective

ii) oblique projection b) isometric projection i) assembly ii) exploded c) orthographic projection i) know the difference between A) first angle projection

B) third angle projection ii) material specification

iii) recognise line conventions A) sectioning B) hidden details C) dimensioning D) standard abbreviations 2. identify the correct procedures for using, storing and caring for measuring and marking out

equipment a) rules b) tape rules c) micrometers

d) vernier callipers e) scribers f) odd leg callipers

g) centre punches h) plumb-lines i) squares j) dividers 3. identify the effects of errors when using measuring and marking out equipment a) parallax errors b) cumulative errors c) use of datums/datum lines/centre lines d) accuracy, benefits and limitations of equipment i) rules ii) tape rules iii) micrometers iv) vernier callipers v) scribers vi) odd leg callipers vii) centre punches viii) plumb-lines viii) squares x) dividers

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4. Identify the correct procedures for using, storing and caring for hand tools used for cutting a) types of saws b) types of files c) types of chisels d) types of drilling machines e) features of drill bits f) work holding methods g) hole sawing h) hand shears (snips) i) punches j) nibblers k) oxy-fuel gas cutting l) types of grinder 5. identify the correct procedures for using, storing an caring for hand tools used for forming a) types of hammers b) bending bars c) vices 6. identify the correct procedures for using and caring for equipment used for cutting and forming a) bench shears b) guillotines c) folders d) box and pan folders e) fly press f) hydraulic press 7. identify the correct procedures for heat treating materials a) annealing b) normalising c) hardening d) tempering

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Outcome 2: Welding using the manual metal arc (MMA) process Practical Activities The candidate will be able to 1. produce fillet and butt welded joints in low carbon steel using the MMA welding process 2. produce welded butt joints in the flat position using the MMA welding process 3. produce tee, lap and corner fillet welded joints in the flat and horizontal welding positions

using the MMA welding process Underpinning Knowledge The candidate will be able to 1. identify the basic equipment set-up for the MMA welding process a) types of power sources available

i) transformers ii) transformers/rectifiers iii) inverters iv) generators

b) current control methods c) welding lead and electrode holder d) return lead and clamp e) workpiece/welding earth f) equipment faults and methods of rectification g) effects of type of current

i) ac ii) dc

2. identify consumables available for welding a) electrodes i) core wire ii) covering b) characteristics of types of electrodes c) electrode sizes 3. identify welding techniques used a) stringer beads b) weaving c) welding in downhand position i) flat ii) horizontal d) welding of types of joints

i) butt ii) corner iii) tee iv) lap

e) types of welds i) butts A) square B) single-vee C) double-vee ii) fillet

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4. identify pre and post-welding conditions a) joint cleanliness b) pre-welding alignment and accuracy checks c) methods of distortion control d) application of pre-heat e) post-weld cleaning

f) weld quality/integrity checks i) types of defects ii) appearance

5. identify methods of distortion control a) presetting b) skip welding c) back-stepping d) tack welding e) pre and post-weld heat treatment f) intermittent welding g) restraint

i) clamping ii) jigs iii) back-to-back assembly

6. identify the benefits and limitations of process compared to MIG and oxy-acetylene welding.

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Outcome 3: Welding using the metal insert gas (MIG) process Practical Activities The candidate will be able to 1. produce fillet and butt welded joints in low carbon steel using the MIG process 2. produce welded butt joints in the flat position using the MIG welding process 3. produce tee, lap and corner fillet welded joints in the fault and horizontal welding positions

using the MIG welding process Underpinning Knowledge The candidate will be able to 1 identify the basic equipment set-up for the MIG welding process

a) types of power sources available i) transformers/rectifiers ii) inverters iii) generators b) voltage control methods i) flat characteristic c) welding lead and torch construction (air and water cooled) d) return lead and clamp, workpiece/welding earth e) equipment faults i) clearing a burn-back f) type of current - polarity

2. identify the functions of a wire feed unit. a) direct control of wire feed rate b) indirect control of welding current c) control of gas flow rate

3. identify the consumables available for welding a) solid wire electrodes b) electrode wire sizes c) function of copper coating

d) electrode storage and handling 4 identify the purpose of gas shielding a) applications for shielding gases/gas mixtures

i) argon for aluminium ii) argon/carbon dioxide mixtures for steels iii) argon/oxygen/carbon dioxide mixtures for steels

b) gas pressure and flow rates 5. The welding techniques used a) weaving b) non-weaving 6. identify the benefits and limitations for process compared to MMA and oxy-acetylene welding

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Outcome 4: Welding using the oxy-acetylene gas process Practical Activities The candidate will be able to 1. produce fillet and butt welded joints in low carbon steel using the oxy-acetylene process 2. produce welded butt joints in the flat position using the oxy-acetylene welding process 3. produce lap and corner fillet welded joints in the flat and horizontal/vertical welding positions using the oxy-acetylene welding process Underpinning Knowledge The candidate will be able to 1. identify the basic equipment set-up for the oxy-acetylene welding process a) cylinders b) pressure regulators

c) flashback arrestors d) hoses e) hose check-valves f) blowpipe/torch g) nozzles 2. describe the function of components of oxy-acetylene welding equipment a) cylinders b) pressure regulator types

i) single-stage ii) two-stage

c) flashback arrestors d) hoses e) hose check-valves f) blowpipe/torch g) nozzles i) types ii) sizes iii) selection 3. identify the correct welding variables

a) gas pressures b) nozzle size c) welding techniques i) rightward ii) leftward

4. state flame conditions a) neutral i) typical flame temperature

b) oxidising c) carburising/reducing d) applications for i) neutral ii) oxidising iii) carburising/reducing 5. identify the products of combustion a) inner core b) outer envelope 6. identify the benefits and limitations of process compared to MMA and MIG welding processes

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Outcome 5: Produce soldered joints Practical Activities The candidate will be able to 1. select the most effective welding process for a given application and quality specification 2. produce a soldered joint to a quality specification Underpinning Knowledge The candidate will be able to 1. identify bonding mechanisms a) surface tension b) welding c) capillary action d) importance of cleanliness 2. state the difference between hard soldering and soft soldering 3. identify processes and equipment a) consumables i) hard soldering (bronze welding) ii) soft soldering iii) fluxes iv) filler rods 4. identify advantages and disadvantages a) hard soldering (bronze welding) b) soft soldering 5. identify typical soldering techniques a) hard soldering (bronze welding) b) soft soldering

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Unit 3 Maintenance of Tractors and other Land-based Machinery

Rationale The aim of this unit is to equip the candidate with the skill, knowledge and understanding needed to remove and replace components from tractors and machinery, carry out planned maintenance and adjust tractors and machinery to manufacturer’s specifications. This unit covers four performance outcomes. 1. Remove components from tractors and machinery 2. Replace components on tractors and machinery 3. Carry out planned maintenance to tractors and machinery 4. Adjust tractors and machinery to manufacturer’s specifications Connection with other awards The unit relates to the Lantra Land-based Service Engineering National Occupational Standards

• Lantra LBSE 7.1 Remove components from tractors and machinery • Lantra LBSE 7.2 Replace components in tractors and machinery • Lantra LBSE 8.1 Carry out planned maintenance procedures • Lantra LBSE 8.2 Adjust tractors and machinery to manufacturer’s specifications

Assessment The outcomes from this unit will be assessed using evidence from: 1. Practical activities The assessment will be by means of a centre set practical assignment

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Outcome 1: Remove Components from Tractors and Machinery Practical Activities The candidate will be able to

1. Service a fuel system on a CI power unit 2. Remove and replace an alternator 3. Check and replace a battery 4. Check and replace lighting units 5. Service a hydraulic system 6. Service and adjust a safety overload device 7. Calibrate a machine 8. Sharpen and adjust a cutting device Underpinning Knowledge The candidate will be able to

1. Interpret engineering information and manufacturers specifications a) component removal b) technique’s used for removal

2. demonstrate types of correct component removal methods and techniques used in the following systems a) engine b) electrical c) hydraulics d) power train e) calibration f) cutting

3. state methods for identifying component faults a) manufacturer’s guidelines b) sensory c) measurement

4. explain methods used for labelling and storage of components for re-use a) mark component orientation for re-use b) label damaged components c) label components for storage, discarding or warranty

5. state manufacturer’s guidelines for the use of tools and equipment a) oil pressure gauge b) hydrometer c) battery tester equipment d) continuity/electrical tester e) multimeter f) hydraulic pressure/flow gauge g) injector tester h) torque wrench i) spring balance j) micrometer k) vernier gauge l) feeler gauge

6. explain reporting lines and procedures for faulty components

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a) non warranty b) warranty, to include manufacturer’s procedures

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Outcome 2: Replace components on tractors and machinery Practical Activities The candidate will be able to 1. Service a fuel system on a CI power unit 2. Remove and replace an alternator 3. Check and replace a battery 4. Check and replace lighting units 5. Service a hydraulic system 6. Service and adjust a safety overload device 7. Calibrate a machine 8. Sharpen and adjust a cutting device Underpinning Knowledge The candidate will be able to 1. Interpret engineering information and manufacturers specifications

a) parts identification b) torque settings c) thread identification d) settings and adjustments

2. demonstrate types of correct component replacement methods and techniques used in the following systerms a) engine b) electrical c) hydraulics d) power train e) calibration f) cutting

3. explain reporting lines and procedures for replacing components a) non warranty b) warranty, to include manufacturer’s procedures

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Outcome 3: Carry out planned maintenance to tractors and machinery Practical Activities The candidate will be able to 1. Service a fuel system on a CI power unit 2. Remove and replace an alternator 3. Check and replace a battery 4. Check and replace lighting units 5. Service a hydraulic system 6. Service and adjust a safety overload device 7. Calibrate a machine 8. Sharpen and adjust a cutting device

Underpinning Knowledge The candidate will be able to 1. describe the types of schedules and related specifications for

a) manufacturer’s maintenance b) seasonal maintenance

2. demonstrate maintenance methods and procedures required by manufacturer’s of tractors and machinery for a) engine b) electrical c) hydraulics d) power train e) calibration f) cutting

3. describe the maintenance records and documentation procedures for a) company b) customer c) manufacturer

4. describe the maintenance authorisation procedures for a) company b) customer c) manufacturer

5. explain the importance of accurately completing records and passing them on to the appropriate person a) job card b) time sheet c) parts requisition form

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Outcome 4: Adjust tractors and machinery to manufacturer’s specifications Practical Activities The candidate will be able to 1. Service a fuel system on a CI power unit 2. Remove and replace an alternator 3. Check and replace a battery 4. Check and replace lighting units 5. Service a hydraulic system 6. Service and adjust a safety overload device 7. Calibrate a machine 8. Sharpen and adjust a cutting device

Underpinning Knowledge

The candidate will be able to 1. demonstrate adjustments following manufacturer’s schedules and related specifications

for a) engine b) electrical c) hydraulics d) power train e) calibration f) cutting

2. state manufacturer’s guidelines for the care and control of tools and equipment a) oil pressure gauge b) hydrometer c) battery tester equipment d) continuity/electrical tester e) multimeter f) hydraulic pressure/flow gauge g) injector tester h) torque wrench i) spring balance j) micrometer k) vernier gauge l) feeler gauge

3. describe how and when to report problems with tractors and machinery following adjustments a) company b) customer c) manufacturer

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Unit 4 Repair of Tractors and other Land-based Machinery

Rationale The aim of this unit is to equip the candidate with the skill, knowledge and understanding needed to assess customer technical requirements and propose solutions to include; diagnosing faults, dismantling, repairing and assembling components, conducting tests and interpreting results on tractors and machinery. The unit covers four performance outcomes. The candidate will be able to: 1 Determine and propose solutions for customers’ technical requirements 2 Diagnose faults in tractors and machinery 3 Dismantle and assemble components to meet specifications 4. Conduct specified testing, analyse and interpret the results of tests on tractors and

machinery Connection with other awards The unit relates to the Lantra Land-based Service Engineering National Occupational Standards

• Lantra LBSE 10.1 Determine customers’ technical requirements • Lantra LBSE 10.2 Propose solutions to meet customers’ technical requirements • Lantra LBSE 11.1 Diagnose faults in tractors and machinery • Lantra LBSE 12.1 Dismantle components • Lantra LBSE 12.2 Assemble components to meet specifications • Lantra LBSE 13.1 Conduct specified testing of tractors and machinery • Lantra LBSE 13.2 Analyse and interpret the results of tests on tractors and machinery

Assessment The outcomes from this unit will be assessed using evidence from: 1. Practical activities The assessment will be by means of a centre set practical assignment

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Outcome 1: Determine and propose for customers technical requirements Practical Activities The candidate will be able to 1. Inspect, test and diagnose faults in a CI power unit 2. Inspect, test and diagnose faults in a power train 3. Inspect, test and diagnose faults in a hydraulic system 4. Inspect, test and diagnose faults in an electrical/electronic system Underpinning Knowledge The candidate will be able to 1. describe the information sources and document types used to provide solutions to customer requirements a) the customer b) past service records c) dealer and manufacturer’s records d) manufacturer’s representatives 2. identify the structure, format and content of a) manufacturer’s representatives b) customer requirements 3. describe how solutions to meet customer technical requirements may be limited by a) organisation’s policy b) procedures and standards of customer care c) limits of your authority d) legislation and regulations e) industry standards f) manufacturer’s guidelines 4. describe the application of legislation, regulators, industry standards and manufacturers’ guidelines for tractors and machinery 5. describe the reporting lines and procedures a) company b) customer c) manufacturer 6. describe the reporting lines and procedures to a) company b) customer c) manufacturer 7. analyse technical information and identify solutions to customer requirements 8. describe methods of writing technical reports and presenting information a) customer b) company c) manufacturer

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Outcome 2: Diagnose faults in tractors and machinery Practical Activities The candidate will be able to 1. Inspect, test and diagnose faults in a CI power unit 2. Inspect, test and diagnose faults in a power train 3. Inspect, test and diagnose faults in a hydraulic system 4. Inspect, test and diagnose faults in an electrical/electronic system Underpinning Knowledge The candidate will be able to 1. demonstrate the use of tools and equipment needed to diagnose faults in a diesel

engine a) dynamometer b) leak-down and compression testers c) injector tester 2. demonstrate the use of tools and equipment needed to diagnose faults in a power transmission a) pressure gauge b) computers/electronic diagnostic aids c) multimeter 3. demonstrate the use of tools and equipment needed to diagnose faults in a hydraulic system a) pressure/flow/temperature gauge b) computers/electronic diagnostic aids c) multimeter 4. demonstrate the use of tools and equipment needed to diagnose faults in the electrical/electronic system a) computers/electronic diagnostic aids b) multimeter 5. explain how the following sources of information would be used to assist with fault

finding a) workshop manuals b) manufacturers data and information sheets c) service bulletins d) computers/electronic diagnostic aids 6. state manufacturer’s instructions for equipment operation, cleaning and storage on the following diagnostic tools a) dynamometer b) multimeter c) pressure/flow/temperature gauge

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Outcome 3: Dismantle and assemble components to meet specifications Practical Activities The candidate will be able to 1. Inspect, test and diagnose faults in a CI power unit 2. Inspect, test and diagnose faults in a power train 3. Inspect, test and diagnose faults in a hydraulic system 4. Inspect, test and diagnose faults in an electrical/electronic system Underpinning Knowledge The candidate will be able to 1 interpret information from manufacturer’s specifications a) workshop manuals b) parts lists

c) modifications and update sheets d) microfiche and computer based media

2. state dismantling and assembly methods used to ensure correct fitting of repair components in the following systems

a) engine b) transmission

c) hydraulic d) electric/electronic 3. explain methods used for recognising component defects in the following systems a) engine

b) transmission c) hydraulic d) electric/electronic

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Outcome 4: Conduct Specified testing, analyse and interpret the results of tests on tractors and machinery

Practical Activities The candidate will be able to 1. Inspect, test and diagnose faults in a CI power unit 2. Inspect, test and diagnose faults in a power train 3. Inspect, test and diagnose faults in a hydraulic system 4. Inspect, test and diagnose faults in an electrical/electronic system Underpinning Knowledge

The candidate will be able to 1 state the manufacturer’s engineering test specifications from a) manuals b) electronic sources c) drawings 2. explain the function and operation of the following types of test equipment a) dynamometer

b) leak-down and compression testers c) injector tester d) pressure gauge – transmission e) pressure/flow/temperature gauge – hydraulic f) multimeter g) computers/electronic diagnostic aids

3. state the relevant methods and procedures used for testing the following systems a) engine b) transmission c) hydraulic d) electric/electronic 4. state methods used to analyse and interpret results from the following tests a) fault finding by logic b) isolation of components c) defining performance against manufacturers data

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Unit 5 Arc Welding Processes in the Land-based Sector

Rationale This unit is concerned with the technology and practices involved in the application of manual arc welding processes. The unit is demanding in terms of technological content and the complexity of the welding that candidates are expected to achieve. The unit is broadly divided into three processes: manual metal arc (MMA), metal inert gas (MIG) and tungsten inert gas (TIG) together with an understanding of electric welding power sources and the practicalities of producing a welded joint. This unit covers five performance outcomes. 1 Prepare the equipment for manual metal arc welding 2 Prepare the equipment for metal inert gas (MIG) welding 3 Prepare the equipment for tungsten inert gas (TIG) welding 4. Produce welded joints that conform to specification Connection with other awards The unit relates to the Lantra Land-based Service Engineering National Occupational Standards

• Lantra LBSE 15.1 Repair and modify components by welding Assessment The outcomes from this unit will be assessed using evidence from: 1. Practical activities The assessment will be by means of a centre set practical assignment 2. Written tests The underpinning knowledge requirements are listed for each outcome. These will be assessed by a multiple choice test covering the four outcomes.

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Outcome 1: Prepare the equipment for manual arc (MMA) welding Practical Activities The candidate will be able to 1. select the welding equipment for a given application 2. prepare the welding equipment for a given application Underpinning Knowledge The candidate will be able to 1. describe leads used a) welding

b) return c) earth d) construction e) rated output (duty cycle) f) faults and maintenance 2. describe electrode holders used a) types b) fully insulated c) partially insulated 3. describe electrodes by their covering type a) cellulosic b) rutile c) basic d) iron powder e) function of coverings

i) facilities arc striking ii) stabilises arc striking iii) assists control of the size and frequency of filler metal globules/droplets iv) protects filler metal from atmospheric contamination during transfer v) protects deposited metal from contamination vi) provides appropriate weld contour vii) prevents rapid cooling of weld metal (thermal blanket effect) viii) provides a flux for the molten pool to remove oxides and impurities ix) supplies additional metal to the weld pool (including alloying elements)

4. describe return clamps used a) types b) clamping mechanisms c) function

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Outcome 2: Prepare the equipment for metal insert gas (MIG) welding Practical Activities The candidate will be able to 1. select the welding equipment for a given application 2. prepare the welding equipment for a given application Underpinning Knowledge The candidate will be able to 1. identify modes of metal transfer a) dip (short-circuiting) b) globular c) spray 2. describe guns used for welding

a) air cooled b) nozzles

i) dip ii) spray d) contact tip i) functions ii) material iii) sizes vi) clearing a burn-back 3. describe electrode wires used for MIG welding

a) sizes i) diameters ii) reels sizes available b) function of deoxidisers c) function of copper coating

4. describe leads used a) welding i) air cooled ii) harness b) return c) earth d) construction e) liners (guide type) i) types ii) faults and maintenance 5. describe return clamps used a) types b) clamping mechanisms c) function 6. describe the gas supply and distribution a) types and applications of gases/gas mixtures used i) argon for aluminium ii) argon/carbon dioxide mixtures for steels

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iii) argon/oxygen/carbon dioxide mixtures for steels iv) argon/oxygen mixtures for stainless steels b) cylinders c) regulators d) gas flow meters e) gas tubes and connectors 7. describe the wire feed unit a) direct control of wire feed rate i) variable speed motor b) indirect control of welding current c) contactor leads i) solenoid valve to control of gas flow rate ii) relay for electrical power

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Outcome 3: Prepare the equipment for tungsten inert gas (TIG) welding Practical Activities The candidate will be able to 1. select the welding equipment for a given application 2. prepare the welding equipment for a given application Underpinning Knowledge The candidate will be able to 1. describe methods of arc ignition a) scratch b) high frequency c) lift start

i) contactor ii) foot pedal/current control

2. describe torches used for welding a) air cooled b) contractor/switch c) back caps d) nozzles e) collet f) collet holder

3. describe leads used a) welding

i) air cooled ii) harness

b) return c) earth d) faults and maintenance

4. describe return clamps used a) types

b) clamping mechanisms c) function 5. describe the gas supply and distribution a) types and applications of gases/gas mixtures used i) argon ii) helium for thick materials and good conductors (aluminium and copper) iii) argon/helium mixtures iv) argon/hydrogen mixtures for austenitic stainless steel b) cylinders c) regulators d) gas flow meters e) gas tubes and connectors

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Outcome 4: Produce welded joints that conform to specification Practical Activities The candidate will be able to 1. select the most effective welding process for a given application and quality

specification 2. produce welded joints in carbon steel, low alloy steel, stainless steel or cast iron to a

given quality specification in lap, tee, corner and butt joints in the flat, horizontal and vertical positions

Underpinning Knowledge The candidate will be able to 1. identify types of joint a) lap b) tee c) butt d) corner 2. identify welding positions a) flat

b) horizontal c) vertical i) up

ii) down 3. describe pre-welding activities and equipment a) cleaning

i) grinders ii) linishers iii) wire brushes iv) oxide removal v) degreasing

b) edge preparation i) square ii) single-vee iii) double-vee iv) edge

c) assembly i) use of tack welds ii) use of clamps d) pre-heat

4. a) describe the techniques used when welding i) fabrications ii) repairs b) describe procedures and techniques used when repairing welding cast iron c) describe back-gouging techniques

5. recognise welding defects (BS EN 25817 – 1992 arc welded joints in steel – guidance on quality levels for imperfections)

6. explain the causes of welding defects

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7. explain how welding defects can be avoided 8. explain how welding defects can be repaired 9. describe post welding activities

a) cleaning i) slag removal ii) splatter removal iii) wiring brushing iv) removal of excess weld metal where required b) visual checks carried out i) defect levels ii) appearance c) destructive and non-destructive testing activities i) penetrant testing for surface flaws ii) leak testing iii) bend tests (root, face and side) vii) nick-break fracture viii) macro examination d) post-weld heat treatment i) normalising ii) stress relief

10. describe the reasons for distortion a) uneven expansion and contraction b) degree of restraint c) identify the types of distortion i) longitudinal ii) transverse ii) angular 11. explain the methods of distortion control a) presetting b) skip welding c) back-stepping d) tack welding e) pre and post weld heat treatment f) intermittent welding g) restraint i) clamping ii) jigs iii) back-to-back assembly 12. list the methods of distortion rectification a) mechanical methods i) peening ii) jacking iii) pressing iv) hammering (planishing) b) thermal methods

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3942 Certificate in Land Based Service Engineering

Centre-devised assignment submission report Part A – To be completed by the centre BOX 1

Centre details Date sent to City & Guilds (dd/MM/yyyy

Centre number Sub centre

0 0Centre name

Name of Examinations Office contact

Telephone number Fax number

E-mail

Name of author of question paper Telephone number

Assignment Details BOX 2

Assignment component number 3 9 4 2 -

Component title

Please complete the following checklist

The assignment submitted Yes No* Covers all practical activities from the Assignment template

Will take a minimum of TEN hours to complete

Can be marked according to the grading criteria provided

Includes the required underpinning knowledge questions

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* Please provide justification for the assignment NOT meeting the set criteria (add separate sheets if required

Please attach a copy of the proposed assignment to this Assignment Submission Form BOX 3 The centre confirms that the assignment contains 1. Assessor guidance notes including

A health and safety statement

The location of where the assignment will take place

The requirements for tools, equipment, materials and data

Notes on the content of the assignment

Notes on preparatory work required by the assessor

Details of evidence and recording requirements

Time considerations

2. Candidate instructions includes

An assignment brief setting the scene or giving a scenario

General guidance notes advising candidates to check they understand requirements

Time consideration

The importance of Health and Safety

Clearly defined tasks – covering all practical activities from the Assignment Template

Recording/reporting sheets to record progress through the tasks

Notes advising candidates on how their evidence should be stored

Any required engineering drawings provided to current standards

Note the centre should allow 6 weeks from the date of submission by e-mail for City and Guilds to agree the assignment

Name (block capitals

Date

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Signed

Please e-mail to centredevised@city-and-guilds.co.uk

Centres which are unable to submit via e-mail must post THREE copies of the proposed assignment to City & Guilds, Centre Devised, 1 Giltspur Street, London, EC1A 9DD. This must be sent EIGHT weeks before intended use.