AUTOMOTIVE INDUSTRY RETAIL, SERVICE & REPAIR - part 65

AURT5712A Analyse and evaluate heavy vehicle engine and fuel system faults 

Automotive Industry RS&R 

468 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

EVIDENCE GUIDE 

Underpinning Knowledge 
(continued) 

•  General knowledge of the types, functions, operations and 

limitations of heavy vehicle engines 

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle fuel systems/components  

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle engine electrical 
systems/components 

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle intake systems/components 

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle exhaust systems/components 

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle lubrication 
systems/components 

•  Detailed knowledge of the types, function, operations and 

limitations of heavy vehicle cooling systems/components 

•  General knowledge of the theory of diagnosis including 

concept, design and planning 

•  Detailed knowledge of the types, functions, operations and 

limitations of diagnostic testing equipment 

•  General knowledge of automotive digital computing 

systems 

•  General knowledge of the methods and processes for 

recording and reporting diagnostic findings and 
recommendations 

Automotive Industry RS&R  

AURT5712A Analyse and evaluate heavy vehicle engine and fuel system faults 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

469 

 

EVIDENCE GUIDE 

Underpinning Skills 

These include a number of processes that are learnt throughout work and life, which are 
required in most jobs.   Some of these are covered by the national key competencies, although 
others may be added.  The questions below highlight how these processes are applied in this 
competency unit.  The number in brackets indicates the level to which the key competency 
needs to be demonstrated where (1) is where work is within set conditions and process, (2) is 
where the management or facilitation of conditions or process is exercised, and (3) is where 
the design and/or development of conditions or process are required. 

How will the candidate apply the following key competency in this unit? 

The candidate will need to: 

Collect, analyse and 
organise information 

 

Research, organise and understand technical information related 
to contemporary heavy vehicle engine and fuel systems, 
monitoring and testing processes, diagnostic methods and 
options and safety procedures. 

 (Level 3)

Communicate ideas and 
information 

 

Communicate ideas and information to enable confirmation of 
work requirements and specifications, coordination of work with 
site supervisor, other workers and customers, the reporting of 
work outcomes and the completion of regulatory, commercial 
and vehicle information systems inputs. 

(Level 2)

Plan and organise 
activities 

 

Plan and organise activities including the planning of analytical 
processes, the establishment of evaluative (success) criteria, the 
preparation and layout of the worksite and the obtaining of 
testing equipment and material to avoid any back tracking, 
workflow interruptions or wastage. 

(Level 2)

Work with others and in 
a team 

 

Work with others and in a team by recognising dependencies and 
using cooperative approaches to optimise workflow and 
productivity. 

(Level 2)

Use mathematical ideas 
and techniques 

 

Use mathematical ideas and techniques to correctly complete 
measurements, calculate analytical requirements, calibrate and 
establish testing equipment and present analytical results. 

(Level 2)

Solve problems 

 

Establish analytical processes, including diagnostic processes, 
which anticipate and allow for risks, cater for both direct and 
indirect evidence, avoid or minimise reworking and avoid 
wastage. 

(Level 3)

AURT5712A Analyse and evaluate heavy vehicle engine and fuel system faults 

Automotive Industry RS&R 

470 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

EVIDENCE GUIDE 

Underpinning Skills (continued) 

Use technology 

 

Use the workplace technology related to systems analysis and 
diagnosis, information research and management systems, 
testing equipment, maintenance equipment, tools, calculators 
and measuring devices. 

(Level 2)

 

EVIDENCE GUIDE 

Resource Implications 

• 

Access to a realistic requirement and objective(s) for 
analysis and evaluation, heavy vehicle engine and fuel 
systems with real or simulated faults, monitoring processes 
and testing equipment appropriate to the objective(s), 
research facilities and technical information and a realistic 
work environment 

Method of Assessment 

• 

Assessment of this competency is most likely to be project 
related under real or simulated conditions and require 
portfolios or other forms of indirect evidence of process.  
Direct evidence may include certification of compliance of 
the final outcome/product or authorisation for use by a 
competent authority 

• 

Assessment must confirm the inference that competency is 
able not only to be satisfied under the particular 
circumstances, but is able to be transferred to other 
circumstances 

Context/s of Assessment 

• 

Assessment may occur on the job or in a workplace 
simulated facility with relevant process equipment, 
material, work instructions and deadlines 

 

 

Automotive Industry RS&R  

AURT5713A Analyse and evaluate heavy vehicle braking system faults 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

471 

 

AURT5713A 

Analyse and evaluate heavy vehicle braking 
system faults  

Unit descriptor 

This unit covers the competency to correctly analyse and 
evaluate heavy vehicle braking systems in order to initiate 
action to sustain, vary or enhance performance. It includes 
failure analysis covering the complex diagnosis of multi-system 
and intermittent faults as well as evaluation of performance 
achievements and variations. It also requires the candidate to 
identify, evaluate, select and record the most appropriate 
response to the stated objective of the analysis and evaluation 
process. 

This unit forms part of the competency inventory for an 
automotive technologist or subject matter specialist. It 
encompasses and builds on trade level competencies. 

 

ELEMENT PERFORMANCE 

CRITERIA 

1.  Identify and confirm 

the work requirement 

1.1 

Work instructions and reports are used to determine the 
nature and objective of the analysis and evaluation 
requirements  

1.2 

Benchmark specifications for correctly functioning heavy 
vehicle engine systems are accessed and interpreted 

1.3 

OH&S requirements including equipment and system 
isolation requirements and personal protection needs are 
observed throughout the work 

1.4 

The effects of any systemic deficiencies/discrepancies or 
faults are identified and confirmed from indirect and/or 
direct evidence 

1.5 

Possible safety impacts of the work are considered and 
responded to in accordance with regulatory and 
enterprise obligations and practices 

2.  Prepare for analysis 

and evaluation 

2.1 

Evaluative criteria are developed/adopted to meet the 
objective of the work 

2.2 

System performance achievements and/or discrepancies 
are identified from an analysis of technical support 
information and available on-board diagnostic systems 

2.3 

The most appropriate analytical and evaluative 
methodology including diagnostic process, sequence, 
tests and testing equipment are developed and/or 
identified and selected from the range of available 
options  

AURT5713A Analyse and evaluate heavy vehicle braking system faults 

Automotive Industry RS&R 

472 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

ELEMENT PERFORMANCE 

CRITERIA 

2. Prepare 

for 

analysis 

and evaluation 
(continued) 

2.4 

Testing equipment is obtained and prepared for 
application in accordance with regulatory, manufacturer/ 
component supplier and enterprise requirements  

2.5 

Tools and material required to support the diagnostic 
process are identified, selected and prepared for use 

2.6 

Heavy vehicle braking system components are prepared 
for the diagnostic process including park-up, isolation 
and cleaning requirements 

3.  Apply the analysis and 

evaluative 
methodology 

3.1 

The selected analytical and diagnostic process is 
followed in accordance with specifications and directions 
and/or the locally authorised method 

3.2 

Tests and testing equipment are applied in accordance 
with regulatory requirements and the manufacturer/ 
component supplier specifications 

3.3 

Analytical and other diagnostic findings are verified, if 
necessary by using reliable alternate or optional 
processes, and documented 

3.4 

Analytical findings and results are evaluated against the 
agreed criteria 

3.5 

Valid conclusions are drawn from the available evidence 
and documented to enterprise requirements 

3.6 

Information and detail related to the analysis and 
evaluation is provided to the appropriate parties in 
accordance with regulatory and commercial obligations 

4.  Select response 

measure 

4.1  Options for responding to the objective or need are 

identified from further research of technical support 
information 

4.2  The most appropriate response option is selected from an 

analysis of the options, the prevailing circumstance, 
regulatory requirements and commercial policies 

4.3  The selected response option is documented and reported 

in accordance with regulatory and enterprise 
requirements and practices 

5. 

Restore the workplace 

 

5.1  Material that can be reused is collected and stored 

5.2  Testing equipment and other support material are cleaned, 

maintained and prepared ready for further use or stored in 
accordance with manufacturer/component supplier 
specifications and enterprise requirements 

5.3  Waste and scrap is removed following workplace 

procedures 

Automotive Industry RS&R  

AURT5713A Analyse and evaluate heavy vehicle braking system faults 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

473 

 

ELEMENT PERFORMANCE 

CRITERIA 

5. 

Restore the workplace 
(continued) 

5.4  Equipment and work area are cleaned and inspected for 

serviceable condition in accordance with workplace 
procedures 

5.5  Unserviceable equipment is tagged and faults identified in 

accordance with workplace procedures 

 

RANGE STATEMENT  

The Range Statement provides advice to interpret the scope and context of this unit of 
competency, allowing for differences between enterprises and workplaces. It relates to the unit 
as a whole and facilitates holistic assessment. The following variables may be present for this 
particular unit: 

Unit scope 

•  The objective of the failure analysis and evaluation process 

may be to determine fault rectification measures, to effect 
variation in system characteristics and parameters or to 
enhance system performance 

•  Braking systems to be covered in this unit are to include 

foundation, ABS, ABS with traction control, air brakes 
(truck and trailer), air brakes (multiple trailer), 
compression braking, vehicle retardants, and air over 
hydraulic systems 

•  Brake timing and balancing are covered 

•  Braking system failures covered by this unit are to include 

air supply capacity, application and release times, brake 
balance, brake drum wear, calibration/adjustment 
specifications, component damage, conductors – piping 
specifications, contamination, friction material 
abnormalities, leaks, pump up times 

•  Braking system failures covered by this unit are to include 

indirect faults caused by the influence of external systems 
which may or may not be faulty in their primary operations 

Unit context 

• 

OH&S requirements include vehicle industry regulations, 
safety management systems, hazardous substances and 
dangerous goods code and safe operating procedures 

• 

Work is carried out in accordance with legislative 
obligations, Australian Design Rules, environmental 
legislation, relevant health regulations, manual handling 
procedures and organisation insurance requirements 

• 

Work requires individuals to demonstrate research, 
analytical, judgement and problem solving skills in the 
diagnosis of faults 

AURT5713A Analyse and evaluate heavy vehicle braking system faults 

Automotive Industry RS&R 

474 

AUR99 Version 4.00 Review by 30 June 2004 

©Australian National Training Authority 

 

RANGE STATEMENT  

Evaluative criteria 

• 

Evaluative criteria, sometimes referred to as success 
factors, detail the criteria against which the achievement 
of the objectives of the analysis are judged. They are to 
include statistically based criteria and may include other 
measures 

Isolation procedures 

• 

Equipment isolation procedures are to industry and 
enterprise standards  

Testing equipment 

• 

Testing equipment is to include air gauges, multi-meter 
and Tappley meter and may include brake timer and 
electronic stethoscope 

Tests 

• 

Tests to be conducted are to include system performance, 
air supply build up time, prime mover and trailer 
application time, park brake application, brake fluid 
boiling point, rotor and drum wear, pad and lining 
thickness, brake pedal travel, handbrake mechanism 
travel, NVH, directional control, ABS operation and 
performance, sensor/actuator and wiring harness integrity, 
sampling (collection and processing) and 
monitoring/analysis of computer-based diagnostic 
systems 

• 

Tests may also include braking during cornering, brake 
roller testing, friction material wear rate, disc drum and 
rotor temperature 

Personal protective 
equipment 

 

• 

Personal protective equipment is to include that 
prescribed under legislation, regulations and enterprise 
policies and practices 

Information and 
procedures 

•  Workplace procedures relating to the use of tools and 

equipment 

•  Workplace procedures relating to reporting and 

communication 

•  Manufacturer/component supplier specifications and 

application procedures for testing equipment and material 

•  Manufacturer/component supplier specifications, 

schematics and operational procedures related to heavy 
vehicle braking systems 

•  Australian Design Rules 

•  Vehicle industry regulations 

•  Vehicle industry publications related to emerging braking 

system technology and technology changes 

 

Automotive Industry RS&R  

AURT5713A Analyse and evaluate heavy vehicle braking system faults 

©Australian National Training Authority 

 AUR99 Version 4.00 Review by 30 June 2004 

475 

 

EVIDENCE GUIDE 

The Evidence Guide identifies the critical aspects, knowledge and skills to be demonstrated to 
confirm competency for this unit. This is an integral part of the assessment of competency and 
should be read in conjunction with the Range Statement. 

Critical aspects of 
evidence 

•  Interpret work order and locate and apply relevant 

information 

•  Apply safety requirements including the isolation of 

equipment and the use of personal protective equipment 

•  Follow work instructions, operating procedures and 

inspection processes to: 

•  minimise the risk of injury to self and others 

•  prevent damage and wastage of goods, equipment and 

products 

•  maintain required production output and product 

quality 

•  Complete failure analyses on a minimum of three (3) 

heavy vehicle braking systems with real or simulated 
multi-system and intermittent faults and identify, evaluate, 
select and record the most appropriate rectification 
measure 

•  Analyse and validate or recommend variations to a 

minimum of two (2) available repair/modification 
procedures for heavy vehicle braking systems 

•  Accurately record and report the diagnostic process and 

findings and recommended rectification for two of the 
above 

•  Work effectively with others 

•  Modify activities to cater for variations in workplace 

context and environment 

Underpinning knowledge 

•  Heavy vehicle terminology and definitions 

•  General knowledge of the concepts, principles and 

processes involved in planning and implementing systems 
analysis and evaluation 

•  Basic electrical theory covering voltage, current, 

resistance, power, magnetics and inductance  

•  Mechanical theory covering the concepts and principles of 

mechanical, hydraulic and pneumatic systems