Volvo Science and Technology Activity Pack 1

Have you got
the drive?
ACTIVITY PACK 1
TO SUPPORT ACHIEVING ALTERNATIVE B, ACTIVITY 1 & 3
MECHANICS: HEALTH & SAFETY AND CHECKLIST
At Volvo Trucks we think it is brilliant that you’ve chosen to work towards the Explorer Science & Technology badge. This resource pack is the
first step in developing your interest in vehicle maintenance, and hopefully driving a passion for technology. When working through these
activities, remember to work safely and check the health & safety warning boxes along the way.
THE APPRENTICE:
LET’S GET MECHANICAL
Here’s your chance to be a technician for the day. You’ve been hired as an apprentice
technician at a busy garage. Your first job is to assess a car or a truck ready for its MOT. Work
your way through the checklist activities, and complete the technician’s report at the end.
Your leader or the vehicle owner will be the customer today. They need to stay with you at
all times and you will need to point out any faults you find. They will also be on hand to
start the ignition and check you follow all the safety procedures.
You will need to complete a report on your car or truck to show your customer that you
have done your job using the checklist.
TICK BOX
COMMENT
*Check all indication lamps in switches
Check ignition switch function and fixing
Check starter motor. How does it sound?
Check all controls and switches
Check all instruments are working properly
Check seat adjustment
Check seat belt condition — do they all work properly?
Check conditions of seats and bunks (if your vehicle has them)
Check fire extinguisher condition and fixing
Check condition of all windows
Check window lifts work well
Check the sun shade and sun visors
Check condition of floors, matting and steps
**Check function of storage bin locks and closing devices
**Check function and sealing of roof hatch
Check engine casing
Test all inside lamps and horn
Check registration plate condition — is it readable and securely attached?
Check condition and fixing of mudguards and mud flaps
Check tyre tread depth
Check tyre pressure and valve caps
Check paint and panels for damage
Check rear-view mirrors
** Some of these are specific to trucks
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ACTIVITY: SAFETY FIRST
Before starting your job, you need to go over some health and safety rules.
Garages are very interesting, and can be dangerous places. Check that your tools are handy and organised and that
you have the correct protective clothing.
1. Look the part
In the motor industry you would expect to work with both very advanced electrical and mechanical equipment. Whilst
taking part in these activities, ensure you wear appropriate clothing and correct PPE (Personal Protective Equipment).
This could include: Protective footwear, hand protection such as disposable rubber gloves and heavy duty (industrial)
gloves, work wear for example overalls. For some checks you may also need to wear plastic protective goggles and a
face mask.
Whilst carrying out checks on the vehicle, ensure you have old cloths and rags at hand.
Before examining a car or truck, check that the engine is switched off and the handbrake/
parking brake is securely on. Make sure that the vehicle is parked on a flat surface and off
road, away from other drivers.
2. Use your eyes
So, gloves on, clipboard and pen in hand, start by walking slowly around the truck or car.
Examine the tyres. A general tyre check should include checking the overall condition of the tyre, air pressure, and
tread depth.
Look at each tyre and check for lumps, bulges or if there are pins, glass or objects stuck in the wheel. These could
cause air to leak out slowly or puncture the tyre. This can be dangerous if it happens while driving along.
Did you know? A car or truck owner can be fined if the tyre does not have enough tread
depth. More importantly, it is dangerous to drive with bald tyres. If a tyre is worn, then the car
or truck can slide across the road in rain and bad conditions.
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3. Watch your tread
Use a tread depth gauge to measure the tread. Examine the tyre and find the most worn or thinnest part of the tread
as it will wear the quickest.
Put the gauge needle right in the middle of the tread (it will not puncture the tyre) and push down until it stops. Take
the reading.
Did you know? Truck tyres can have a retread. A new rubber retread can be bonded to the old
worn tyre. For every 10 new truck tyres sold in the UK, 8 retreads are sold*.
(*Source: Tyre Industry Federation)
4. Air pressure
If you can’t get hold of an air pressure gauge, you could use one available at a petrol station.
Did you know? Having the right pressure in your tyres can help save on fuel and reduces the
amount of carbon dioxide (CO2) produced by a car or truck.
Under-inflated tyres use more fuel and wear out more quickly, they can also overheat! Over-inflated tyres (tyres that
are pumped up with too much air) have less grip on the road surface and can make the vehicle hard to steer.
Each car or truck has a correct air pressure for its particular make. You will find this in the car or truck’s manual, or
inside the petrol cap door. It will look similar to this:
Tyre sizeFront tyresRear Tyres
165/70R14 T 81
2.3 BAR / 34 PSI
2.1 BAR / 31 PSI
Tyre size for a Truck Front tyres
315/60/R22.5 (LOAD INDEX 154) 8BAR /116PSI
Rear Tyres
8BAR /116PSI
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Did you know? Air pressure goes up in warm weather and down when it is cold.
Check a car or truck tyre air pressure
1. Take off the dust cap on the valve
2. F ix on the pressure gauge and note the reading.
If your tyre needs extra air, you can add more using an
air pump, available at many petrol stations. If the tyre is
overinflated (according to the pressure chart) you can
let some air escape whilst the dust cap is off until the
reading is correct.
3. W
hen your tyre reaches the right pressure, take off the
air pipe and re connect the dust cap. You will need to
measure the pressure on all four tyres.
You should also check the tread and the pressure of the
spare tyre, so it is ready to use in an emergency.
If the tyre has a puncture, bald treads or a bulge, it will need to be changed.
OPTIONAL ACTIVITY: CHANGING A TYRE
1. Locate the spare tyre and check the condition
2. If you are outside, put on the emergency hazard lights on.
3. Make sure the car or truck is on a flat surface on solid ground. Wedge something under the wheels on the
side that is not being lifted.
4. Use a screwdriver to help remove wheel cover, or wheel trim if there is one.
5. Use the wheel wrench to loosen the wheel nuts whilst the car is on the ground. Loosen by a half a turn in an anticlockwise direction.
6. Put the jack together and use the tyre jack to raise the wheel.
8. Once the vehicle is raised a little, but before the wheel you are raising is off the ground, push the spare wheel
under the body of the car/truck. This will act like a safety cushion if it slips.
A car or truck can easily slip off the jack. NEVER get under a vehicle while only the jack is supporting it.
9. Keep raising the vehicle. When you have the vehicle jacked up make sure that you are using axle stands that are
able to take its weight. Make sure your axle stand is positioned under the vehicle.
10. Unscrew the nuts. Once the wheel is just clear of the road, unscrew the wheel nuts in diagonal pairs and remove
them. Put them together in your pocket so you don’t lose them.The wheel will be heavy and dirty. Work slowly
and carefully as you remove the wheel.
11. Fit the spare. Make sure the spare tyre is the right way round. Fit the wheel nuts in diagonal pairs and turn until
they are tight using your fingers. Put the old tyre flat under the car as a safety cushion as before.
12. L ower the car/truck. Using the jack, lower the vehicle until the tyre touches the road. Now lightly tighten the
wheel nuts using the wheel brace. Remove the old tyre from underneath the vehicle.
Finish lowering the car/truck and remove the jack.
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ACTIVITY: LOOKING OUTSIDE
Balancing Act
While walking around the vehicle, notice if it seems to
be leaning to one side, or seems a little lower on one
side than the other. Does the wheel arch on the driver
side seem closer to the tyre than the passenger side?
Your vehicle should be parked on flat, even ground. Is
the vehicle sitting even? If not, there could be a loose
coil or spring, or a problem with the vehicle suspension.
Did you know? A suspension system
is made up of springs. These allow a
truck (or car’s) tyres and axle to move
independently from each other, rather than
if they were fixed directly to the frame.
Each time the truck goes over bumps
or potholes in the road, the suspension
system helps to absorb the impact so that
the tyres don’t bounce up and down.
In a flap
Now look at the wheels. Has the car or truck been fitted
with mud guards or spray flaps behind the wheels? These
flaps help to keep the body of the vehicle clean by stopping
the wheels spraying up mud and dirt from the road.Check
that these are clean or they will not be any use.
Checking lights
Look at all the lights,from the front, back and sides. Cars
and trucks have different kinds of lights for different
conditions and to signal the driver’s intentions to other
road users. Ask your customer (the car owner) to turn on
each set of lights for you in turn.
• Are the full beams bright enough?
• Do the dipped headlights work?
• What about the left and right indicator signals? Compare
the brightness of left and right lights, and rear lights.
• Are all the lights clean? Lights will not be effective if
they are covered in mud and smears.
• Locate the button for the hazard warning light. Do
they work?
Hazard lights warn other road users that there is a problem
or that a driver is stopping unexpectedly, and they will give
the car/truck a wide berth, or move out of the way.
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Walk to the back of the vehicle. Ask the owner/leader to press the footbrake and note whether the rear red brake
lights come on. Do they work on both sides?
Now check the reverse lights. They warn cyclists, pedestrians and other drivers that the vehicle is about to move
backwards. The driver will need to switch on the ignition, but not start the engine. Ask them to put the car/truck in
reverse gear. You will be able to see white lights on both sides at the back.
Did you know? Nils Bohlin, an engineer at Volvo, invented the three-point seat belt in 1959.
The three-point seatbelt was widely adopted because Volvo opened up the patent so that any
manufacturer could use it.
Inside Job
Now check that the dashboard lights work, too. These will usually come on automatically when the vehicle’s lights
are switched on.
Look at the display in front of the driver’s seat. When the engine is running, some of the lights stay on so the driver
can read the control panel, but the others flicker on momentarily when the ignition is switched on and then go off.
These include the battery light, petrol gauge and oil level icons. If one of the dash lights stays on, it can signal a
major problem with the car or truck. Often a warning alert will sound to draw your attention to a problem.
How many of these system icons do you know already? If the icon stayed lit up, what would it mean?
Water works
Find the out how to activate the windscreen wipers, both front and rear window. Trigger the water spray first. Do the
wipers work on all speeds?
If the wipers create smears or marks over the screen rather than making it look clearer, then the wiper blades may
need a clean, or they could be damaged.
Clean the blades with a soapy sponge along the edge of the blade. Try the wipers again. Has that made a difference?
Being able to see out of the windows is essential or you can risk causing an accident. Check the positioning of the
side and rear mirrors. Do they need a clean?
Check the air conditioning and heating. Can you change the settings to direct the air flow to the windows to help
de-mist them, or to the driver’s hands and feet? There may also be a separate switch to activate the rear window
heater to de-mist the car.
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Sitting comfortably
Check the seat adjustment works well especially for the driver’s seat. If you’re unsure how to raise, lower and adjust the
seat check the vehicle manual. Most importantly, do all of the seat belts work properly including middle belts? If there
are any child seats check that these are securely attached. Remember to check the bunks if your truck has them.
Did you know? Truck drivers can spend a long time sitting in the same position. It’s
recommend that truck drivers vary their seat position every 30-60 minutes. A driver’s elbows
should be as close to their sides as possible while holding the steering wheel. Mirrors and
instruments should be easily visible whilst sitting comfortably. The driver should be able to
press pedals all the way down without twisting or moving away from their seat. Knees should
be no higher than the hips, and the front of the knees should not rest against the seat edge.
The curved lower back (the lumbar area) should ideally be supported.
Listen
Ask the car or truck owner (your customer) to switch on the engine. How does it sound? When a vehicle is idling (the
engine is running but the vehicle is not moving) the engine should still sound smooth. If it sounds like it is hiccupping
or stuttering as if it is about to stall, then it could signal a problem that needs to be checked.
ACTIVITY: UNDER THE HOOD
It is important to get to know the different parts of a car or truck.
Your first task is to open the bonnet and secure it safely.
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GHS-01
Explosives
Self-reactive substances and mixtures, Corrosive to metals
types A, B Organic peroxides,
types A,BSkin corrosion
GHS-05
SevereExplosive
eye damage
Test yourself: You might come across these signs when you start examining the car or truck.
Corrosive
Flammable gases, aerosols, liquids or solids
Acute toxicity (Cat 4)
Self reactive substances and mixtures
Skin and eye irritation
Pyrophoric liquids and solids
GHS-07
Skin sesitisation
Self-heating substances andGHS-06
mixtures Acute toxicity (Cat 1 - 3)
GHS-02
specific target organ toxicity
NEW
Substances and mixtures, wich in contact
Toxic/Very
Respiratory tract irritation
with water emit flammable gases
Highly/Extremely Harmful/Irritant Toxic
Narcotic effects
Organic peroxides
flammable
These signs are to advise technicians and anyone checking a car or truck to wear
suitable protective rubber gloves
sensitisation
and goggles to protect eyes and skin. If you see theRespiratory
toxic sign then
you will need to wear a mask too. Do not touch
your face with your rubber gloves or other exposedGerm
part ofcell
skin.
mutagenicity
GHS-08
Carcinogenicity
If you see any of the signs, you will need
to take extreme
care when handling fluids or checking those parts of the
Reproductive toxicity
NEW
Oxidising
gases, liquids and solids
engine. You will alsoGHS-03
need an adult
alongside.
No current specific symbol
specific target organ toxicity
Aspiration hazard
Oxidising
Use either
Oil Check
Check the type of oil recommended
your vehicle’s
Compressed
gases,make
liquids and solids
and model. This will be in the vehicle’s handbook.
GHS-04
Liquefied gases
No current symbol
GHS-09
Hazardous to the aquatic environment
Refrigerated
gases
NEW make sure
Wearing rubber gloves,
the hood liquefied
is open and
Dissolved
gases
secured. Look for the oil dipstick.
(See picture.)
1. Pull it out slowly and wipe it clean with an old rag
or piece of kitchen paper. You will see little lines with
MIN and MAX written on them.
Dangerous for the
environment
to metals
2. Now put the dipstick back inCorrosive
the oil tank.
GHS-05
Skin corrosion
3. Pull the dipstick out of the tube again and look at
Severe
the highest point the oil reaches
on eye
the damage
markers. If it
is below or near to the minimum marker, you need
to top-up your oil by about 0.5 litres depending on
where the mark is.
GHS-06
How to fill the oil tank
Corrosive
Acute toxicity (Cat 1 - 3)
Harmful
1. Find the engine filler cap. It should be marked but if you are not sure then Toxic/Very
look in the manual!
There may be a few
Toxic
caps for different fluids and you want to get it right.
2. Unscrew the cap. Use the funnel and carefully pour in some oil. Use less rather than more as overfilling is bad for
the engine. Try not to spill any oil. Wipe up any spills immediately as it is a fire risk.
3. Screw the lid back on securely.
4. It is better to wait until the car or truck has been driven a short distance before checking again. If you do, make
sure the vehicle has not been driven for two hours so that the engine is cold, and that it is parked on flat ground
once again.
Smear proof
Check the windscreen wiper fluid. Locate the screen fluid reservoir — the bottle where the screen wash is kept.
You will probably need to dilute the fluid with water. Check the car manual first and then follow instructions on
the bottle. Then top up the fluid as needed. Remember to replace caps securely and wipe around the outside of the
container afterwards.
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MECHANIC’S REPORT
Once you have given your car or truck it’s MOT, it is time to fill in the report.
QUESTION
COMMENT
1. Did you check the tyre tread depth?
What was it?
What is the legal tyre tread depth?
What is the name of the tool used to check the tyre tread depth?
2. Did you check the spare wheel?
What is a jack for?
Why is it important to check your spare wheel is in good condition and that you carry a jack? 3. Did you check the lights. Tick the ones that you found and tested.
Headlights - Left Right
dipped
full beam
fog lights
Rear lights - Left Right
Reverse lights
Brake lights
Front indicators
Side indicators
Hazard warning lights
Dashboard lights
How did you check they were working?
4. Oil check.
Did you have to add any more engine oil?(Yes/no/tick box squares)
What is the name of the metal stick with the MIN and the MAX markers?
Why is it important that the car/truck is on a flat surface before you check the oil levels?
5. Did you check the windscreen wiper fluid? (square tick box)
If you filled it, what did you use?
6. Did you see any of these warning signs?
What do they mean? Where did you see them?
Did you know? Volvo Trucks run an apprenticeship technician scheme? Most technicians start out
as an apprentice with a dealer or with a trucks company, such as Volvo Trucks. If you’re interested in
finding out more visit the About Us section on the Volvo Trucks UK website volvotrucks.com
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