Work applies to electrical units and assemblies that are fitted in light and heavy vehicle, mining, construction, agricultural, motorcycle, outdoor power equipment and marine environments.

Work requires individuals to demonstrate some judgement and problem-solving skills in managing own work activities and contributing to a productive team environment.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for work

1.1. Workplace instructions are used to determine job requirements

1.2. Workplace health and safety (WHS) requirements are observed throughout the work

1.3. Procedures and information are sourced and interpreted

1.4. Tools and equipment are identified for effective removal, replacement and testing procedures

2. Remove electrical and electronic units and assemblies

2.1. Correct information is accessed and interpreted from manufacturer and component supplier specifications

2.2. Electrical and electronic units and assemblies are removed using approved methods, tools and equipment

2.3. Assistance from a licensed person is sought in relation to air conditioning and LPG/CNG/LNG systems and component removal

2.4. Removal activities are carried out according to industry regulations and guidelines, workplace health and safety (WHS) legislation, and workplace policies and procedures

2.5. Units and assemblies are handled and stored according to manufacturer and component supplier requirements

3. Replace electrical and electronic units and assemblies

3.1. Correct information is accessed and interpreted from manufacturer and component supplier specifications

3.2. Electrical and electronic control units and assemblies are replaced using approved methods, tools and equipment

3.3. Assistance from a licensed person is sought in relation to air conditioning and LPG/CNG/LNG systems and component replacement

3.4. Replacement activities are carried out according to industry regulations and guidelines, WHS legislation and workplace policies and procedures

4. Test and reprogram electrical and electronic units and assemblies

4.1. Testing procedures on replaced electrical and electronic control unit and assemblies are carried out

4.2. Options for diagnosing faults are identified and used, using appropriate tools and diagnostic techniques

4.3. Checking and testing are achieved without causing damage to components or systems as a result of inappropriate testing procedures

4.4. Faults are identified from test results and causes of faults are determined

4.5. Diagnosis findings are reported according to workplace procedures, including recommendations for necessary repairs or adjustments

4.6. Reprograming options are analysed and those most appropriate are selected

4.7. Component replacement and programing procedures are carried out according to workplace procedures and manufacturer and component supplier specifications

4.8. Post-repair testing is conducted and results are documented according to workplace procedures and relevant legislation

5. Clean up work area and maintain equipment

5.1. Material that can be reused is collected and stored

5.2. Waste and scrap are removed following workplace procedures

5.3. Equipment and work area are cleaned and inspected for serviceable condition according to workplace procedures

5.4. Faulty equipment is identified, tagged and isolated according to workplace procedures

5.5. Operator maintenance is completed according to manufacturer and component supplier specifications and site procedures

5.6. Tools and equipment are maintained according to workplace procedures

Required skills

communication skills to:

follow verbal and written instructions

clarify workplace instructions and determine job requirements

gain information from appropriate persons and assistance as required

initiative and enterprise skills to:

apply learning when replacing electronic units and assemblies in complex automotive electrical systems

recognise a workplace problem or potential problem and take action

learning skills to identify sources of information, assistance and expert knowledge to expand skills, knowledge and understanding

literacy skills to:

read and follow information in written job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

obtain and record measurements

document required repairs and parts

numeracy skills to:

test, measure and analyse test equipment results compared to desired system performance

assess tolerances and apply accurate measurements and adjustments

planning and organising skills to:

plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed on time

identify risk factors and take action to minimise them

problem-solving skills to:

refer problems outside area of responsibility to appropriate person and suggest possible causes

seek information and assistance as required to solve problems

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

recognise limitations and seek timely advice

follow workplace documentation, such as codes of practice and operating procedures

teamwork skills to apply knowledge of own role to complete activities efficiently to support team activities and tasks

technical skills to use workplace technology and tools relating to removing and replacing vehicle electrical and electronic units and assemblies, including:

specialist tools and equipment

electrical measuring equipment

technology skills to:

operate a range of electrical and electronic diagnostic test equipment

use technology to collect, analyse and provide information

Required knowledge

WHS regulations, requirements, equipment, material and personal safety requirements, including:

individual state and territory legislation

codes of practice

personal protection needs

procedures for removing, replacing, testing and reprogramming electrical and electronic units and assemblies and post-repair testing

wiring harness and loom fabrication techniques

procedures for removing and replacing wiring harnesses and looms

soldering procedures and techniques

terminal crimping and connector repair techniques

cable types and sizes and current carrying capacity

various types of wiring systems found in vehicles, including:

basic wiring

twisted pair

shielded wiring

CAN-bus and databus networks

techniques for reading and interpreting technical information, wiring diagrams and graphic symbols

diagnostic and testing procedures, including:

analysis of system operation using electrical test equipment and other industry-relevant test equipment

visual, aural and functional assessments, including:

component damage and wear

component corrosion

water and moisture ingress

repair procedures, including:

component removal and replacement procedures

component and associated system adjustment procedures

The evidence guide provides advice on assessment and must be read in conjunction with the Performance Criteria, required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge.

A person who demonstrates competency in this unit must be able to:

observe safety procedures and requirements

select methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

remove and replace a minimum of four units and assemblies to workplace, manufacturer and component supplier requirements, including:

one supplementary restraint system module

one body control module

one engine or powertrain control module

complete final functional test to specification

present vehicle and equipment in a condition that complies with workplace requirements.

Context of, and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting.

Assessment is to occur:

using standard workplace practices and procedures

following safety requirements

applying environmental constraints.

Assessment is to comply with relevant:

regulatory requirements

Australian standards

industry codes of practice.

The following resources must be made available for the assessment of this unit:

workplace location or simulated workplace

material relevant to removing and replacing electrical and electronic units and assemblies

equipment, and hand and power tools appropriate to removing and replacing electrical and electronic units and assemblies

specifications and work instructions.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with the application of required skills and knowledge.

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure correct interpretation and application.

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate the needs of diverse clients.

Assessment processes and techniques must be culturally sensitive and appropriate to the language, literacy and numeracy capacity of the candidate and the work being performed.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Workplace instructions may include:

electronic or hard copy instructions

verbal instructions

written instructions.

Job requirements may include:

effective unit and assembly removal and replacement techniques

reprogramming procedures to enable replaced unit and assembly to communicate with vehicle CAN-bus systems

diagnosis and repair methods, processes and equipment.

Workplace health and safety requirements may include:

personal protective clothing and equipment

hazards associated with high voltage ignition systems

safe use of tools and equipment

safe handling of material

use of fire-fighting equipment

workplace safety policies and procedures

workplace first aid equipment

hazard control, including control of hazardous materials and toxic substances.

Procedures and information may include:

verbal, written and graphical instructions

signage

work schedules, plans and specifications

work bulletins and memos

material safety data sheets (MSDS)

diagrams and sketches

regulatory and legislative requirements relating to automotive industry

Australian Design Rules

engineer's design specifications and instructions

workplace work specifications and requirements

instructions issued by authorised workplace or external persons

Australian standards

vehicle service requirements and repair manuals.

Tools and equipment may include:

hand tools

testing equipment, including multimeters and ohmmeters

heat-gun or blower

heat shrink sleeving and flexible conduit

terminals and connectors

electrical tape.

Electrical and electronic units and assemblies may include:

electrical and electronic units and assemblies integral to the vehicle’s CAN-bus network, including:

engine control unit (ECU)

engine control module (ECM)

powertrain control module (PCM)

body control module (BCM)

supplementary restraint systems (SRS).

Options for diagnosing faults may include:

continuity testing

insulation testing

isolation and repair to located faults

replacement of blown fuses or circuit breakers

replacement of damaged connectors or terminals

visual inspection and evaluation of components.

Inappropriate testing procedures may include:

intrusive testing (which must not be performed as it is not a recommended test and repair method), which includes:

back probing terminals and connectors and fuse holders with inappropriate test probes

probing terminal and connectors with inappropriate test probes

pushing sharp probes and objects into wiring insulation.

Faults may include:

open circuits

short circuits

high resistance circuits

damaged insulation

frayed wires

burnt wiring

water and moisture ingress

connector damage

terminal damage

diagnosis trouble codes (DTC) being set.

Reprogramming options may include:

service programming system (SPS)

manufacturer programming code and relearn procedures

original equipment manufacturer (OEM) specific programming code.

Post-repair testing may include:

validating effectiveness of the replacement or repair action

confirming that reported fault has been rectified

confirming that no other faults are present as a result of the replacement and the reprogram or repair action.

Electrical

Unit sector

Technical – Electrical and Electronic

This unit contains employability skills.