motor vehicle mechanics worksheet pack · 2020. 3. 18. · a work for the same employer b are about...

www.aspireap.org.uk Mechanics Workbook

Motor Vehicle Mechanics

Worksheet Pack V1.0

This worksheet pack contains a variety of different worksheets that have been

designed to be researched and completed by students at home to assist in

their understandings within the subject of motor vehicle mechanics.

Can you spot and circle the workshop hazards? Picture A – Vehicle Workshop

Can you spot and circle the workshop hazards? Picture B – Vehicle Workshop

Can you spot and circle the workshop hazards? Picture C – Workshop Stores

Can you spot and circle the workshop hazards? Picture D – Body Workshop

Can you spot and circle the workshop hazards? Picture E – Body Workshop

Worksheet – Manual Handling

Candidate:

Date:

Assessor:

Learning Objectives

Identify safe manual handling practices and procedures

Identify common manual handling equipment used in vehicle workshops

Use appropriate manual handling procedures when carrying or lifting during vehicle maintenance or repair


~ 2 ~

10 Steps to Lifting

When you are lifting an object in the workshop, in the class, at home, or

anywhere else; it is important that you follow the 10 steps to lifting. These are

shown here:

1

Make sure that the route that the load is to travel through

is safe and clear from obstruction giving you a clear

journey to travel

2

Make sure that the area where the load is going to be

placed is clear from all obstructions and safe to put the

load.

3

Assess the load, make sure that it is evenly weighted and

of a safe weight to lift. Also that the load is not containing

any objects that come under COSH regulations. If the load

is to heavy to lift ask for some help or use lifting apparatus

4

Place your feet shoulder width apart ensuring that you

have a stable base to lift with

5

Stand as close to the load as possible and bend you

knee’s so you are able to take hold of the load

6

Ensure that your back stays in a straight position and your

head is kept upright

7

Straighten your arms when lifting and keep the load as

close to your body as possible, this reduces the amount of

pressure that is applied to the spin when lifting

8

Take a firm grip of the load ensuring that it is not going to

slip or fall

9

Lift the load by straightening your knees.

10

Keep the load as close to your body as possible and

always lift with your knees never lift with your back


~ 3 ~

Manual Handling

4.1

To lift a load you should always try to:

A Stand with your feet together when lifting

B Bend your back when lifting

C carry the load away from your body, at arm’s length

D divide large loads into smaller loads

4.2

You need to lift a load from the floor. You should stand with your:

A feet together, legs straight

B feet together, knees bent

C feet slightly apart, knees bent

D feet wide apart, legs straight

4.3

You have been told how to lift a heavy load, but you think there is a better way to do it. What should you do?

A Ignore what you have been told and do it your way

B Ask your workmates to decide which way you should do it

C Discuss your idea with your supervisor

D Forget your idea and do it the way you have been told

4.4

To lift a load safely, you need to think about:

A its size and condition

B its weight

C whether it has handholds

D all of the other answers


~ 4 ~

4.5

When you lift a load manually, you must:

A keep your back straight and use the strength in your leg muscles to lift

B make sure there are always two people to lift the load

C use a crane or other lifting device to pick up the load

D move the load as quickly as possible

4.6

You are using a wheelbarrow to move a heavy load. Is this manual handling?

A No, because the wheelbarrow is carrying the load

B Only if the load slips off the wheelbarrow

C Yes, you are still manually handling the load

D Only if the wheelbarrow has a flat tyre

4.7

You are moving a trolley to move a heavy load. The trolley loses a wheel. You still have a long way to go. What should you do?

A Carry the load the rest of the way

B Ask someone to help you pull the trolley the rest of the way

C Drag the trolley on your own for the rest of the way

D Find another way to move the load

4.8

You need to move a heavy load over a long distance. What is the safest way to do it?

A Pick up the load and run all the way

B Tie a rope around the load and pull it

C Roll it end-over-end all the way

D Use a wheelbarrow or trolley


~ 5 ~

4.9

Your new job involves some manual handling. An old injury means you have a weak back. What should you do?

A Tell your supervisor you can lift anything

B Tell your supervisor that lifting might be a problem

C Try some lifting then tell your supervisor about your back

D Tell your supervisor about your back if it gets injured again

4.10

If you have to twist or turn your body when you lift and pace a load, it means:

A the weight you can lift safely is less than usual

B the weight you can lift safely is more than usual

C nothing, you can lift the same weight as usual

D you must wear a back brace

4.11

You have to move a load that might be too heavy for you. You cannot divide it into smaller parts and there is no one to help you. What should you do?

A Do not move the load until you have found a safe method

B Get a forklift truck, even though you can’t drive one

C Try to lift it using the correct lifting methods

D Lift and move the load quickly to avoid injury

4.12

You need to move a load that might be too heavy for you. What should you do?

A Divide the load into small loads if possible

B Get someone to help you

C Use an aid, such as a trolley or wheelbarrow

D All of the other answers


~ 6 ~

4.13

You have to lift a heavy load. What must your employer do?

A Make sure your supervisor is there to advise while you lift

B Do a risk assessment of the task

C Nothing, it is part of your job to lift loads

D Watch while you lift the load

4.14

If you wear a back support belt:

A you can lift any load without being injured

B you can safely lift more than usual

C you could face the same injury of risk as not wearing one

D it will crush your backbone and damage it

4.15

You need to lift a load that is not heavy, but it is so big that you cannot see in front of you. What should you do?

A Ask someone to help carry the load so that you can both see ahead

B Get someone to walk next to you and give directions

C Get someone to walk in front of you and tell others to get out of the way

D Move the load on your own because it is so large anyone in the way is sure to see it

4.16

You need to move a load that is heavier on one side than the other. How should you pick it up?

A With the heavy side towards you

B With the heavy side away from you

C With the heavy side on your strong arm

D With the heavy side on your weak arm


~ 7 ~

4.17

Someone is going to help you lift a load. It is important that both of you:

A Work for the same employer

B are about the same size and can lift the same weight

C are about the same age

D are right-handed (or both left-handed)

4.18

You have to move a load while sitting, not standing. How much can you lift safely?

A Less than usual

B The usual amount

C Twice the usual amount

D Three times the usual amount

4.19

You need to reach above your head and lower the load to the floor. Which of these is not true?

A It will be more difficult to keep your back straight and chin tucked in

B You will put extra stress on your arms and back

C You can safely handle more weight than usual

D The load will be more difficult to control

4.20

Which part of your body is most likely to be injured if you lift heavy loads?

A Your knees

B Your back

C Your shoulders

D Your elbows


~ 8 ~

4.21

Who should decide what weight you can lift safely?

A You

B Your supervisor

C Your employer

D The Health and Safety Executive

4.22

What is the safest way to found out if a load is too heavy to lift?

A Pick it up quickly then put it down

B Walk round the load, and look at it from all sides

C Find out the weight of the load

D See if you can hold the load at arm’s length

4.23

You have to carry a load down a steep slope. What should you do?

A Walk backwards down the slope to improve your balance

B Carry the load on your shoulder

C Assess whether you can still carry the load safely

D Run down the slope to finish quickly

4.24

Under the regulations for manual handling, all employees must:

A wear back-support belts when lifting anything

B make a list of all the heavy things they have to carry

C lift any size of load once the risk assessment has been done

D make full use of their employer’s safe systems of work

Worksheet – Waste Disposal In mechanics

Name:

Date:

Tutor:

Working in the automotive industry involves generating a variety of wastes both toxic and non toxic which will need to be disposed of accordingly. Looking at the list below, write down how you would best dispose safely of the different types of materials.

Remember, these are all materials becomes ware and tare on vehicles.

Material Disposal Method PPE When Handling

Used engine oil

Oil filter

Used air filter

Spark plugs

P a g e | 2

Brake pads

Brake disc

tyres

battery

engine belt

Suspenson springs

Worksheet – Mechanics Tools

Candidate:

Date:

Assessor:

In this exercise you will presented with a list of tools that you will encounter during the plumbing section of the course. Write down what each tool is used for and some of the risks associated with the tool in the spaces provided.

At the end of the worksheet you will need to explain how you will manage the risks you have highlighted.

Mechanics Tools


Candidate:

Date:

Assessor:

Tools Purpose How to use safely Potential hazard Possible defect Safe storage


What tools am I suppose to use???

Think of the following vehicle maintenance issues and identify the correct tools that you would use for that task.

Task Tools required

Brake pad change

Oil change

Vehicle inspection

Bolt fell deep in engine bay

Clean a brake calliper


To remove the spring coil

Raise car up to change the exhaust pipe

To balance a car wheel

Preparing workshop equipment for use


In the interest of health and safety it is essential that we receive training on any workshop equipment to prevent any potential injury from occurring. The items below identify a number of workshop equipment that needs to be handled with care both during and after use. Prepare a training manual with a step by step information guide on how to use the following equipment in the workshop safely.

Please give a step by step guide on how to correctly use the two post lift to lift a small car in for maintenance and identify what should done after use.

______________________________________________________________________

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Identify the other machines operated by the air compressor and the potential hazards associated with using this machine. State how this machine should be switched on and maintained for safe operation. ______________________________________________________________________

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Give a step by step guide on how to use the tyre changing machine starting from the point of how to the machine should be switched on to operating the machine. ______________________________________________________________________

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Worksheet – Vehicle Construction Materials

Candidate:

Date:

Assessor:

Learning Objectives Identify common materials in the construction of vehicles.

Vehicle Construction Materials and Properties

The construction of a motor vehicle requires a variety of materials in order to complete one car. Listed below are various parts of a vehicles construction identifying each parts material and suggest an advantage and disadvantage of each material type.

Worksheet – Vehicle Construction Materials

Item Material used Advantage Disadvantage

Tyre

Wheel rim

Chassis

Windows/windscreen

Bumper

Front & rear lights

Radiator hose

Brake pipes

Brake disk

Car seats

Valeting

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INTRODUCTION TO VEHICLE VALETTING

Name of Student............................................................................

Name of Teacher...............................................................................

Valeting

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What type of products are used in valeting for

Cleaning each these areas?

Wheels

Car Dash Car body

Car seats & Carpets

Windscreen

Plastic Wing Mirrors &Car Bumpers

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Valeting

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Environmental Agency

Pollution prevention guidelines for valeting Causing or allowing pollution is a criminal offence

This guidance covers vehicle washing and cleaning by all methods,

including

Automatic wash systems

Washing by hand

Using high pressure or steam cleaner

At all sites, including

Retail premises

Business and industrial premises

Public and car parks

Former petrol filling stations

Any effluent and run-off from vehicle washing and cleaning activities

can damage the environment and pollute rivers, streams, burn and

ground water.

Dirt, brake dust, traffic film residue and oil that are washed off are all

pollutants. The cleaning agents you use (including biodegradable or

traffic film removers) are very poisonous to river life if you cause

pollution you are breaking the law and spoiling your environment.

Dirty water or run –off from vehicle washing and cleaning carried out as

a business or industrial activity is called Trade Effluent. Whether you’re

cleaning one vehicle or a fleet of Lorries you must arrange collection

Valeting

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and disposal of effluent to prevent pollution. It’s illegal to discharge

trade effluent to the environment or into drains without permission.

Pprocedures for washing a car

1

2

3

4

5

6

7

8

9

Warning! Remember make sure the vehicle doors, windows are closed and the vehicle

is in a cool place and all sponges, leathers and polishing cloth are kept clean,

If you drop it wash it before using on the vehicle again

Valeting

[Type here]

What equipment do you use for what job?

Car Shampoo Car

Wax

Car Restorer

Car Compound

Glass Cleaner

Wheel Blacker

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Valeting

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How To Valeting A Vehicle Interior

Vacuuming

Remove the floor mats. Vacuum the seats, and the carpet. Using the proper attachment, reach under the seats, around the pedals and the area between front seats and central console. Vacuum floor mats separately.

There are number of upholstery cleaning agents available. Simply spray evenly on the seat or door upholstery and rub vigorously. Then, wipe it thoroughly with a dry cloth. If you don't have an upholstery cleaner, a laundry detergent will work as well. Mix some detergent with warm water. Dip a clean cloth into it, squeeze out well - you want barely moist cloth. Work harder on dirty areas. When you finished, dry out well with a clean, soft dry cloth. Be careful with water inside the car - if the water gets into electrical components it may cause problems. Similarly, you don't want water to get inside your seats or under the carpet - it could cause corrosion, stains and mould smell.

Use soft brush attachment to vacuum the dashboard

and doors. Be careful not to damage knobs vents

and sticking parts. Use the same attachment

vacuuming the seats. Leather seats are very easy to

damage, be careful no to scratch them with the

vacuum hose.

Valeting

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Cleaning fabric seats and door upholstery

Cleaning the carpet

Cleaning and polishing the dashboard

Clean a dashboard, central console, and other plastic parts with a barely moist cloth. Use very small amount of laundry detergent to remove the stains. Dry with a clean soft dry cloth. To make it shiny, spray plastic polish and spread it evenly with soft brush. Don't spray directly on the stereo, use brush instead.

You can clean the carpet the same way you cleaned the seats and upholstery. Spray evenly with the carpet cleaner and rub vigorously. Then, wipe it thoroughly with a dry cloth. The laundry detergent will work on the carpet as well. Again, don't soak the carpet with water, it will cause mould smell and corrosion under the carpet. Dry it out as fast as you can.

Valeting

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Dry-polish gently with clean soft dry cloth. Polish not only makes the dashboard shiny, it protects the plastic. All you need to do after, is just use a soft duster periodically and your dashboard will look like new for a long time.

How to get rid of musty smell from the air conditioner

If you experience that unpleasant musty smell from the vents when the air conditioner is turned on, you can try one of the odor treatments you can buy in your local auto accessories store. It kills the bacteria and removes that mildew smell. Here I used one from Wynn's® that you simply spray into outside air intake vent (check directions on the can). Clogged air conditioner drain tube and accumulation of leaves and other debris under the cowl cover also may cause damp mildew smell. Ask the mechanic to check it when you do your next oil change.

Have a go at valeting your parents car at home…

Worksheet – Vehicle Braking Systems

Candidate:

Date:

Assessor:

Learning Objectives

Learn how to safely work on a vehicle braking system

Learn the components of non- abs braking system.

Learn how braking systems operate

Be able to carry out routine maintenance on vehicle braking systems.

Credits to pass 4

In order for any moving object to stop it will need some form of braking system in place which works on the principle of resistance. For example an aeroplane uses wind resistance in the form of reverse thrust to help it to stop.

In relation to a car the braking system works using friction force.

PPE Required

UNDERSTANDING VEHICLE BRAKING SYSTEMS

Cars are primarily known to use a combination of both drum and disk brakes. Due to disk brakes being more effective than drum brakes, this is the reason why they are used on the front wheels of a car due the increase in weight when a vehicle begins to brake.

The diagram below shows the typical configuration of a braking system on a car.


Task

Looking at the picture above explain your own understanding of how disc brakes operate, by naming the components starting from the brake pedal through to the disk brakes.

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HOW DISK BRAKES OPERATE

Now that you have gained some understanding of how a disk brake operates name the items labelled above and state the purpose of the item.

Label No.

Name of item Purpose

1

2

3

4

5

6

1

2 3

5

4

6

7

8

9

10


7

8

9

10

Brakes quiz

1. Give three main reasons why a car baking system needs to be different from the brakes on a bicycle?

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2. Name three advantages for disk brakes over drum brakes.

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3. Name two reasons for having a brake fluid reservoir.

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4. What is the main purpose of the vacuum booster in the braking system?

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5. Why is it important to have a bleed nipple on the brake

calliper.

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6. What is the main purpose of the wheel hub?

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7. Name the main reason for a combination valve

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Observation questions.

What information can you use to tell if a car brakes needs to serviced.

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Name the step by step procedure for removing and replacing a set of brake pads.

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Name the step by step procedure for replacing a set of brake shoes

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Name the tool used to adjust the hand brake cable.

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Is the hand brake best adjusted with the hand brake on or off? State your reason for you answer.

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Name three hazards associated with bleeding a cars’ braking system?

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Handbrake Adjustment


Explain the purpose of the drum brake.

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Explain the basic principle of how drum brakes work.

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How does the hand brake work with the drum brake to hold the car in a stationary

position _

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Name two ways in which the hand brake cable can be adjusted. Please specify the

location of the adjustment.

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Hydraulic Components

Identify the primary reason for hydraulic unit on a braking system to be in front of the vehicle controls.

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From the diagram above identify three items that operates as part of the hydraulic

system.

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motor vehicle mechanics worksheet pack · 2020. 3. 18. · a work for the same employer b are about...

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