Pirtek 10 Day Induction Programme

PIRTEK INDUCTION

1 0 DAY T R A I N I N G P R O G R AMM E

UK 0800 38 24 38 ROI 1800 74 78 35 www.pirtek.eu

CARDINAL RULES

Work in a safe methodical way at all times, ensuring my safety and those around me

I will

Conduct a thorough Risk Assessment before commencing work

I will

Wear the correct PPE appropriate for the task and site rules

I will

I will not

Cut corners to save time

Depressurise and isolate equipment before attempting to remove any components

I will

I will never

Position myself under a suspended load that is not supported by appropriate props

I will drive

Safely and responsibly giving consideration for other road users

I will not

Operate any equipment that I am not trained or authorised to operate

I will not

Arrive for work under the influence of drugs or alcohol

Respect all site rules and procedures

I will

I will go home every day free from injury or ill health, as a result of the above

Name

Centre

Date

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

At Pirtek we pride ourselves on the extensive courses we offer our network of staff with a particular priority placed on Health & Safety in all environments. Our Induction programme is a City & Guilds accredited programme which is a highly intensive programme designed to ensure all of our staff members have the skills to select and assemble Pirtek products and components to the highest level. We also offer a number of tailor made courses to both our franchise centres and to our customers. MORE THAN A TRAINING PROVIDER...

Discover the benefits of... working with a first class organisation

Our mission is to provide the fastest and most convenient service available today - 24 hours a day, 365 days a year Pirtek was formed in 1988 and has grown to become the number one provider of fluid transfer solutions and on-site repairs Specialising in hydraulic hoses, pipe fittings & couplings, Pirtek has service centres and on-site teams working in UK and Europe Pirtek is committed to on-going and continuous improvement in the service we offer our customers

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INDUCTION TRAINING

01

DESIGN AND APPROVAL This Programme has been designed by PIRTEK (UK) PLC and is approved for induction training of all new members of staff in Franchise centre’s. All trainees’ records will be held PIRTEK (UK) PLC in conjunction with City & Guilds, security and invigilation procedures. Failure to notify PIRTEK (UK) PLC of new recruits’ makes them ineligible sitting City & Guilds examinations. HEALTH AND SAFETY In addition to the technical modules covered the trainee will also receive a health & safety session delivered by a competent person. From this session the trainee will have an understanding of the following: Health & Safety at work act 1974 > General duties of employers and employee’s > Explanation of the health & safety law poster > Management of health & safety at work regulations 1999 Regulation 3, risk assessments Safe methods of working > Understanding of what a safe method of work is > Understand the principles of preparing a safe method of working Risk assessments > Understanding the definition of hazards and risks > The competent person and what is “suitable and sufficient” > The language of risk, the principles of risk assessment and following the five steps 1. Identification of hazards 2. Decide who may get harmed 3. Evaluation of the risks arising from the hazard and introduce control measures 4. Record the findings 5. Review the assessment Supporting information The trainee will be shown various safety media DVD’s associated with risk assessments.

OBJECTIVES The objective of this On the Job Induction Training Programme is to ensure that trainees develop, maintain and improve the skills, competencies and knowledge specified below to the level of productive application required by management under working conditions. SKILLS TO BE ACQUIRED The skills to be acquired in this Programme are: > An understanding of Health & Safety legislation > The ability to conduct risk assessments > Understand the principles of a safe system of work > The ability to identify specific hose ends amongst the range of hose ends > The ability to identify specific hose end adaptors amongst the range of adaptors > The ability to identify specific hose types amongst the range of hoses > The ability to assemble hoses according to Pirtek procedures > The ability to skive the hose where necessary > The ability to crimp the assembled hose using the required machinery > The ability to select appropriate components > The ability to demonstrate familiarity with the service vehicle > The ability to accurately complete associated paperwork > The ability to prospect for new business > The ability to conduct a service call MEANS OF IMPARTATION These skills will be imparted throughout the instruction periods by demonstration, explanation and hands on application to be followed by related periods of closely supervised practice and assessment. The supervisor will keep close watch of the trainee throughout the Programme. The supervisor will correct errors in the trainee’s application of these skills, deal with the trainee’s questions and provide the trainee feedback on progress and results. Assessment throughout this Programme is to be completed after the instruction period during periods of closely supervised practice per program module. During these periods the supervisor will allow the trainee to perform the above tasks themselves, whilst keeping a close watch, correcting errors and providing feedback. EXPECTED PROGRAMME OUTCOMES At the end of this Programme the trainee will be able to perform all the tasks necessary to perform his role as a Mobile Service and Sales Technician or member of the workshop staff under safe working conditions according to Pirtek standards.

The trainee will undertake a practical exercise using the site specific safe method of work

The trainee will sit a short exam at the end of this module

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

Allow trainee time to observe the workshop in operation > Explain the procedures in servicing a client’s needs > Emphasise the importance of the serviceman as the company’s face > Emphasise the importance of first impressions > Emphasise the importance of appearance, presentation and attitude > Explain the concept of empathy for the client’s position to the trainee > Introduce to the trainee the method used in locating and identifying products requested by the client Allow trainee time to become familiar with common products > Supply the trainee with product catalogues and allow them time to read and study the catalogues > Ensure the trainee is able to read and understand the catalogues > Supply the trainee with a range of hose ends, adaptors and ferrules and have the trainee consult the catalogues to identify the parts > Reassure the trainee that it takes practice to become familiar with the entire range of products and that product knowledge will be covered in greater detail later in the Programme A3. Procedures in event of fire or disaster An outbreak of fire anywhere on the site is a possibility for which every employee must be on constant alert. Most fires have small beginnings and the best time to stop a fire is when it is small. This can be done using certain basic knowledge of fire control. The following fire safety procedures will be outlined to all employees: > Locating emergency exits > Raising the alarm at discovery of fire > Locating emergency telephone > Notifying fire wardens > Assembling at a common emergency evacuation point A4. Familiarization with the MSU and geographical area Prior to the trainee attending induction training at the national training centre, the trainee is required to accompany an experienced MSST or multiple MSST’s. This will give the trainee an insight into what daily operations are expected of the trainee. It is a good idea to familiarize the trainee with geographical the area in which he will be situated once he has completed the full induction Programme. Once the full induction Programme has been completed and Pirtek Uk have authorised the trainee to return to his centre with full certification, it is at the licensee’s discretion as to when the trainee will be allowed to enter his territory in his MSU un supervised. If the licensee is not happy to send the trainee into his area, then further training, instruction and supervision is required before the Licensee is satisfied.

KNOWLEDGE INSTRUCTION PERIOD: Please note, module A is designed to be delivered at the MSST’s centre. The module shall be delivered by the Licensee, centre manager, or senior personnel. Module A: Induction, Familiarisation and Safety OBJECTIVES At the end of this module the trainee will be able to: > Demonstrate familiarity with the company structure > Demonstrate familiarity with company procedures > Demonstrate familiarity with physical surroundings > Demonstrate familiarity with service procedures > Demonstrate correct procedures in the event of an emergency involving fire

A1. Introduction Induction lecture from management: > Company structure > Management structure > Staff structure Worker responsibilities: > Job description > Work standards > Company policies > Company procedures > Wage and salary procedures

The Training Programme: Attendance of Induction training at the national training centre Questions and Answer Period: to allow the trainee to ask any unanswered questions.

A2. Familiarisation

Familiarise the new employee with his environment: > Introduce the new employee to fellow staff members > Explain the other staff members position in the Franchisees staff structure > Describe the other staff members role

Take the new employee on a tour of the premises > Point out staff amenities > Point out first aid facilities > Point out secure areas > Point out any hazardous areas > Point out the location of safety equipment

> Explain the layout of the workshop > Explain the layout of the service area

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INDUCTION TRAINING CONTINUED

INSTRUCTION PERIOD: The following modules are to be conducted at the national training centre. Module B: Identifying Hose Ends Visually - 1

OBJECTIVES At the end of this module the trainee will be able to: > Identify and differentiate between components > Locate and identify products in the product catalogue > Identify, locate and test a complementary fitting Test the seat angles

What is to be done?

How is it done?

Points to ensure

Identify and differentiate between components

Locate and identify hose ends

Locate and identify ferrules

Locate and identify relevant and different types of hoses

Note the difference between concave and convex seat fittings

Differentiate between hose end fittings

Inspect and seat of two like size hose ends

Differentiate between seat angles

Differentiate between thread pitch

Note: the most common thread forms are BSP, JIC and METRIC

Identify and differentiate between thread forms

Using an example fitting, compare the seat form, thread form and type of fitting to engineering diagrams to identify the component in the product catalogue

Locate and identify fittings in the product catalogue

Note the series number and name of the thread form of the example fitting already identified using the catalogue.

Identify a complementary fitting

Using the catalogue as a guide, estimate the complementary fitting

Note the series number and thread for of the possible fitting

Estimate the size of the example fitting

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

Module B: Identifying Hose Ends Visually – 2

What is to be done?

How is it done?

Points to ensure

Locate the possible complementary fitting

Use the series number to locate the possible complementary fitting in the storage shelves

Ensure the thread forms mate correctly. Note that where the thread does not fully penetrate, this indicates that the thread forms are incompatible

Test the potential complementary fitting

Screw the two fittings together until they seat off

Where components do no mate, locate another component from the catalogue

Note the series number and the thread form type of the new possible complementary fitting

Locate the new possible complementary fitting

Use the series number to locate the possible complementary fitting in the storage shelves

Use the correct dash size and screw the two fittings together until they seat off

Test the possible complementary fitting

Ensure the male thread fully penetrates the female fitting

Ensure that the seat angles are identical

Test the seat angles

Take a black marking pen and fully colour the male seat

Screw the two components together so that the male seat fully contacts the female seat

Unscrew the components and note the marking on the male fitting

Ensure that the marking on the male fitting is a continu- ous unbroken line around the male seat

Note: not all hose attachments are the threaded type, they may be staple locks or even flange attachments.

If the design can endanger peoples Health, Safety or welfare if the ports are crossed, make sure that different thread forms are used for the hoses, so that the hoses cannot be crossed. See modules N

Hydraulic system design: There will be occasions when you will need to design and install a series of hoses. As an example, pipe up a power pack from open ports.

Identify what thread is in the power pack port, use the correct size and thread for the port adaptor.

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INDUCTION TRAINING CONTINUED

INSTRUCTION PERIOD Module C: Identify Hose End Adaptors using the Catalogue - 1 OBJECTIVES

At the end of this module the trainee will be able to: > Identify adaptors, determine seating arrangement, size and form of thread

> Determine whether the fitting is parallel or tapered > Determine specifications of alternate end of adaptors > Determine sealing arrangement of the adaptors

What is to be done?

How is it done?

Points to ensure

Using the adaptors product not catalogue locate alike adaptors

Note catalogue drawings are drawn to scale

Identify adaptor

Determine the seating and arrangement on both ends of the fitting

Note which end of the fitting has convex seating arrangement

Using the scale supplied in the catalogue determine the corresponding thread and dash size from the thread OD by reading right to left

Measure the external diameter of the male fitting with a pair of vernier calipers to determine the thread size i.e. OD

Determine the size and the form of the thread

Using a thread pitch gauge the number of threads per inch

Determine the threads measure per inch

Having determined the threads per inch, note the thread form from the table supplied in the catalogue

Visually inspect the adaptors by placing the vernier calipers on the thread. The arms of the vernier should contact every thread in order for the fitting to be parallel

Determine whether the fitting is a parallel or tapered fitting

Determine the specifications of the other end of the adaptor

Use the same procedure outlined above

Module C: Identify Hose End Adaptors using the Catalogue - 2

What is to be done?

How is it done?

Points to ensure

After determining the thread form, size and seating arrangement of both ends of the adaptors, combine the thread form codes to locate the series number in the catalogue

Locate the series number in the product catalogue

Note: whilst using the vernier caliper use the metric scale.

Parallel threads rely on a separate seal which may be identified visually

Determine the sealing arrangement of the adaptors

Tapered threads rely on the thread itself and the use of sealing compound eg. Thread tape

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

INSTRUCTION PERIOD Module D: Identifying Hose Types - 1

> Determine the lay line > Locate hose in Pirtek Hose Catalogue and determine dash size > Identify type of hose reinforcement and whether spiral or braid > Determine size of the hose

OBJECTIVES At the end of this module the trainee will be able to:

What is to be done?

How is it done?

Points to ensure

Interpret the lay line

Note the SAE or DIN number

Note the size of the hose

Note the working pressure of the hose

Using the information above locate the hose in the Pirtek Hose Catalogue

Locate the hose in the catalogue

Locate the SAE number in the table supplied in the catalogue

Determine the dash size of the hose

Read off the dash size of the hose

Identify the type of hose reinforcement

Locate any exposed reinforcement on the hose

Module D: Identifying Hose Types – 2

What is to be done?

How is it done?

Points to ensure

Determine whether the reinforcement is spiral or braid

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Cut the hose

Note that low pressure hoses are composed of a synthetic non-metallic reinforcement

Inspect the number of reinforcements in the hose

If it is not possible to determine the type of hose through any of the procedures outlined above, refer to the application that the hose is used for and the type of equipment the hose is employed on

Note that low to medium pressure hoses are a one wire braid

Note medium to high pressure hoses are usually a two wire braid High pressure hoses are usually four wire spiral reinforcement Ultra high pressure hoses are usually six wire spiral reinforcement

All hose sizes are determined by measuring the inside diameter

Determine the size of the hose

Measure the ID of the hose using a vernier caliper

INSTRUCTION PERIOD Module E: Assembling a Hose - 1

OBJECTIVES At the end of this module the trainee will be able to: > Select the required components

> Set up the cut off saw > Cut the hose to length > Assemble the hose

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INDUCTION TRAINING CONTINUED

What is to be done?

How is it done?

Points to ensure

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Select the components

Locate two hose tails to suit the hose size

Locate two appropriate ferrules

Locate corresponding hose

Place hose in measuring tray and align the end of the hose with the required measurement

Measure hose to length

Mark the cut off point on the hose

Position guide pins on the bed appropriate of the saw size to be cut

Set up the saw

Cut the hose to length

Brace the hose in the saw using fitted the bracing handle

Ensure safety goggles are on before proceeding further

Switch the saw on using the start button

Guide the hose firmly into and against saw blade ensuring a clean cut

Do not drag the hose

Module E: Assembling a Hose – 2

What is to be done?

How is it done?

Points to ensure

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Assemble the hose

Place appropriate ferrules on hose ends

Lightly lubricate the tail of the fitting

Place tail of fitting into hose and push home fully

Repeat above process for the other end of the hose

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

INSTRUCTION PERIOD Module F: Skiving a Hose - 1

OBJECTIVES At the end of this module the trainee will be able to: > Assemble machinery, determining correct mandrel > Position the mandrel in the external skiving tool

> Determine the machine settings > Skive the hose externally > Perform an internal skive

What is to be done?

How is it done?

Points to ensure

Place the external skiving tool into the reusable machine and hammer home the chuck using a soft face hammer

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Assemble machinery

Determine the correct mandrel

Select the mandrel according to the hose size

Position the mandrel in the external skiving tool

Remove previous mandrel through the use of Allen key, reposition the new mandrel and secure into position with an Allen key

Adjust external skiving tool to correct setting

Determine the machine setting

Refer to SWAGE MANUAL Note the hose type, series number of the tail to be used and ferrules type to deter- mine the length of the external skive

Module F: Skiving Hose – 2

What is to be done?

How is it done?

Points to ensure

Using a vernier caliper, position the vernier against the shoulder of the external skiving tool and extend the base of the caliper to correspond to the length of the skive already determined in the last step Loosen the skiving mechanism with an Allen key and adjust the skiving mechanism so that the external edge of the skiving tool corresponds to the measurement on the vernier calipers

Set the length of the external skiving tool

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Ensure the hose has been squarely cut before skiving

Skive the hose

Lubricate the mandrel

Ensure the skiving tool is set to the correct depth so that the reinforcement is not damaged

Place the hose on the mandrel to a point where the external edge of

Ensure that the hose is skived in an anti-clockwise direction when skiving externally

Holding the hose firmly over the mandrel and using the foot peddle hose

Ensure safe goggles are fitted before activating machine

Select the appropriate internal skiving tool to correspond with the internal diameter of the hose Lubricate the internal skiving tool, change the direction of the machine from anti-clockwise to clockwise or from reverse to forward

Perform an internal skive

Ensure that safety goggles are fitted before proceeding further Inspect the interior of the hose to ensure wires have not frayed, as they will act as an oil path during operation

Place the hose over the mandrel

Holding the hose firm against the Internal skiving tools shoulder depress the foot pedal and skive out the inside of the hose

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INDUCTION TRAINING CONTINUED

INSTRUCTION PERIOD Module G: Crimping the Assembled Hose - 1

> Determine the crimp diameter > Determine the die size > Prepare the crimping machine > Crimp the ferrule

OBJECTIVES At the end of this module the trainee will be able to:

What is to be done?

How is it done?

Points to ensure

From the dash size of the hose determine the crimp diameter from the charts supplied

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Determine the crimp diameter

Using the charts supplied, locate the size of dies to be used

Determine the die size

Prepare the crimping machine

Place the appropriate dies into the crimping machine

Ensure all the dies are from the same set

Switch the machine on

Adjust the diameter setting to compensate for the difference between the die size and the crimp diameter e.g. for a crimp diameter of 20.8 using size 19 dies add 1.8 to the diameter dial setting

Prepare to crimp the hose

Contract the dies within 10 mm of the hose

Position the hose in the crimping machine ensuring that the hose end protrudes beyond the dies

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Measure the ferrule once crimped to ensure it complies with crimp diameter specified on the crimp chart Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Hold down the die contraction switch and crimp the assembly

Crimp the ferrule

Module F: Skiving Hose – 2

What is to be done?

How is it done?

Points to ensure

Deduct the measurement of the actual crimp from the crimp diameter specified on the chart

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Adjust the crimp where necessary

Measure the ferrule once crimped to ensure it complies with crimp diameter specified on the crimp chart

Crimp the remaining ferrule

Use the process outlined above in module G 1.

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

INSTRUCTION PERIOD Module H: Selecting Components - 1

> Determine the attributes of the component using the STAMPED method > Select fittings and hose tail types > Determine the ferrule to be used > Cut the hose to length and assemble

OBJECTIVES At the end of this module the trainee will be able to:

What is to be done?

How is it done?

Points to ensure

Using the following anagram always determine the: S ize of the hose T emperature range under which the hose operates A pplication the hose is to be used for (Including the Bend Radius) M edium flowing through the hose P ressure the hose will have to withstand(Allow pressure surges) E nds and connections to be used on the hose (Size) D elivery time required by the customer

Determine the attributes of the component

Determining the size o the hose f

Note the size always refers to the internal diameter of the hose

In an emergency increase the internal diameter. Never decrease, as this restricts flow

The size of the hose will always remain the same as the given application

Determine the temperature at which the hose will be used

Always ascertain whether the hose will be for a use other than hydraulic oil and if so, ascertain from the client the temperature at which the hose is to be used.

Module H: Selecting Components – 2

What is to be done?

How is it done?

Points to ensure

Always ascertain from the client whether there are external influences upon the hose in the nature of heat or chemicals and the manner in which the hose is fitted to the machinery

Determine the application

Always check that the medium flowing through the hose is within the tolerance of the hose groups specified in the Pirtek Hose Catalogue

Establish the medium

Determine the medium flowing through the hose

If other than hydraulic oil check chemical resistance guide for correct selection of hose for the application

Consider the pressure

Low pressure hoses range up to 500 psi

Medium pressure hoses range from 500 to 2000 psi

High pressure hoses range from 2000 to 4000 psi

Super high pressure hoses range from 4000 to 6000 psi

Ultra high pressure hoses range in excess of 6000 psi

Pressure in the Hose Catalogue is expressed in bars. To convert this to pounds per square inch multiply the figure by the constant of 14.5 or alternatively check the pres- sure conversion table in the catalogue

With the size, temperature, application and medium already determined, check that the type of hose selected complies with the specifications in the catalogue

Where there is a choice between skived type hoses and non-skived always use non-skived type hoses

Selecting fittings

Refer to the ferrules and tails diagram in the Pirtek Parts Catalogue to determine the type of ferrule and hose tail type to be used

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INDUCTION TRAINING CONTINUED

Module H: Selecting Components – 3

What is to be done?

How is it done?

Points to ensure

Selecting hose tail types

500 series is a low pressure tail

100 series reusable is low-medium pressure

800 series swage is medium-high pressure

800 series multi-spiral is high to very high pressure

Ensure 800 series are skived externally if required

400/1400 series inter-lock/ 1800 none interlock is very high to super high pressure

Ensure 400/1400 series are skived internally and externally

Using Pirtek Hose Catalogue select the appropriate series tail fitting to the hose selection previously specified

Note: ferrule sizes correspond to hose sizes. i.e. for a half inch hose the ferrule size will also be a – 8

Determine the ferrule to be used

Determine the end fittings

Refer to a sample or specifications provided by the customer

Note the type of seat in the end i.e. either convex or concave

Note: The numerals100, 200, 300, 400 500, 600, 700,800, 1400,1800, 3700 and 3800 when used in conjunction with the tail series refer only to the tail of the fitting

To determine the thread type of the end find a complementary opposite fitting

Take the estimated complementary fitting and screw into the end fitting supplied by the client and ensure the two seat out accordingly. If so the estimated fitting is the correct fitting as specified in the product catalogue

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

Module H: Selecting Components - 4

What is to be done?

How is it done?

Points to ensure

Cutting a hose to length

Measure the sample given in the measurement tray

Note the overall length

Place the fittings against the measuring tray at the length determined by the customer’s sample

Place second fitting hard against the first step of the tail of the first fitting

Place the hose end flush with the first step of the second fitting

Mark off the cutting point at the end of the measuring tray accordingly

Adjust the guides on the cut off saw according to the hose diameter

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Cut the hose

Refer to procedure entitled ‘Hose assembly procedure’ P (P) 62.

Assemble the hose

Use the procedure outlined in Module G

INSTRUCTION PERIOD Module I: Familiarisation with the Van - 1

> Learn and identify the location of components, fittings and machinery > Maintain and operate the service vehicle’s crimping machine > Operate the service vehicle’s cut off saw

OBJECTIVES At the end of this module the trainee will be able to:

What is to be done?

How is it done?

Points to ensure

Identify the location of hoses fittings, ferrules, cut off saw crimper, safety equipment vice and dies

The layout of the van is universal in every centre the van is kept to this layout

Learn the location of the components throughout the van

Maintaining the service vehicle’s crimping machine

Remove all dies from crimper through use of die removal tool

Check the oil level

Remove oil cap

Remove dip stick

Ensure oil stays within the permissible range as measured by dip stick

Top up oil as required

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INDUCTION TRAINING CONTINUED

Module I: Familiarisation with the Van - 2

What is to be done?

How is it done?

Points to ensure

Displace die screw with spanner and insert 90° handle into hole in die holder

Lubricating the main dies

Lift the die holder manually and lubricate between the base and the body of the die holder and the crimping machine

Repeat the process for the other side of the machine by pushing down on the 90 degree handle to lever the die holders on the top of the machine away from the wall of the crimping machine

Ensure all wiring is intact and no wires are frayed or cut

Operating the crimping machine

Place the key in the isolation switch and switch “on”

Using the crimp chart supplied, select the appropriate dies and position in the die holders

Set the diameter control measurement according to the crimp chart supplied

To activate the machine, press the button for contracting the dies. Wait for the machine to automatically cut out

To stop the machine in an emergency release button at any time

To open the crimping machine press the button for retracting the dies

Always ensure that the isolation switch is off after using the machine, particularly when the van is in transit

Ensure when the cutting hose that limited pressure is applied to the hose as forcing the hose through will stall the blade Check regularly for wear on blade. The needs changing when rubber marks appear ½ inside of blade

The cut off saw is operated in the same manner as that in the workshop, however the on/off switch is located on the guide handle

Operating the cut off saw

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

INSTRUCTION PERIOD Module J: Completing Paperwork – 1

Note: This is only applicable if the MSST’s XDA /Orbit is out of order. Full training and instruction regarding operation of the XDA/orbit will be demonstrated during induction training at the national training centre. For full operating procedures of the XDA/Orbit, refer to Pits/PVO manual/user guide pages 67 onwards. Special instructions for CRM usage can also be found in the CRM training guide. All of the above documents can be found in the centre or on the Pirtek intranet.

OBJECTIVES At the end of this module the trainee will be able to: > a) Complete a Work Order Form > (b) Complete the Daily Time Records

Module J (a): The Work Order

What is to be done?

How is it done?

Points to ensure

Completing the Work Order Form Write the customer’s name and the address at which the service took place

Specify whether a service charge was incurred

Record the date

Record the number of the van

Record the customer order number

Always obtain an order number from the customer

If the customer asks for this to be completed ensure this is completed as it enables a reference for the customer

Record the machine number

Record a contact name of a relevant person

Specify the length of hose in metres supplied and the code of hose supplied

Specify the number and code of ends supplied

With any cancelled Work Order, take two copies and hand in with the reason why for approval by the manager

Specify the number and code of ferrules supplied

After completing the above insert the number of fully assembled hoses supplied

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INDUCTION TRAINING CONTINUED

Module J: Completing Paperwork – 2 / Module J (A): The Work Order

What is to be done?

How is it done?

Points to ensure

Total the number of assembled hoses and record in the bottom box of the supplied column beside assembly charge

Ensure that a the work carried out is written, brief description of i.e. the nature and the type of work carried out

Where an assembly charge is not to be charged do not write the number of assemblies beside the word ‘assembly charge’

Complete the time the job began

Complete the time the job finished

Complete the total amount of time for the job

Always ensure that a signature of a person who authorised the work is obtained and ensure their name is printed next to the signature

Complete the machine and weld section. Where components have been machined and welded, circle the ‘machine & weld’ section and specify the number of components machined and welded

Module J: Completing Paperwork – 3

Module J (B): The Daily Time Records

What is to be done?

How is it done?

Points to ensure

Completing Daily Time Records

Insert name, day and date

Insert time in and time out for each job

Insert each customer’s name

If service call, ensure invoice number is recorded, for a quick call where work performed, ensure Work Order Number is recorded

Specify whether the call was a quick call, a new call or a service call

Specify the number of labour hours involved with each customer, include any appropriate remarks

Total the number of hours and complete time started and time finished column

Record the total number of hours, number of new call hours and total number of service call hours

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PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

INSTRUCTION PERIOD Module K: Prospecting for Business - 1

Establish contact with target customers allocated to your territory and introduce Pirtek products and services

OBJECTIVES At the end of this module the trainee will be able to:

Ensure all relevant information is noted on the XDA/Orbit

> Maintain active customer calling > Maintain target customer calling > Maintain the CRM package

Give important or requested information to the sales manager

After completing a job, contact the customer within a few days and check that the customer is satisfied with the Pirtek product/service

Operations Maintain active customer calling

Rectify any areas of dissatisfaction as soon as possible

Key Points Take the time to develop a genuine and friendly relationship with the individual who is responsible for authorising work. Stay friendly with clients to ascertain if any work is available or, where they are being serviced by a competitor, whether or not they are happy with that service and if there is an opportunity to promote another aspect of Pirteks service. Always monitor the performance of competition with the customer. Take advantage of any lapse in service by competition. Take the time to learn and remember particular products a customer uses

If the client is satisfied, ask whether they are aware of any other businesses that could benefit from Pirtek products or services and try to obtain a contact name

Remember: any information obtained on a sales call shall be logged on the XDA/Orbit

Operations Maintain target customer calling

Key Points Always be aware of new industry and/or civil engineering projects that may be starting up in your territory Ask to see the appropriate persons within the organisation who are responsible for maintenance and/or purchasing Where the maintenance supervisor or purchasing officer is not available, speak with people on the shop floor to establish who the appropriate contacts are within the organisation If it is opportune, introduce yourself to the contact at the target customer and outline Pirtek products and services using a Pirtek Sales Presentation Binder or catalogue.

Tactfully establish: 1. Who the customer is currently using and why 2. What products and services the customer uses 3. Why the customer is using those products and services

If it is not convenient then suggest a time in the future when you might be able to call back to discuss Pirtek products and services. Discuss difficult customers with the sales manager/franchisee. Establish an approach which may break down the customer’s barriers. Use Pirtek unique benefits such as tagging, ISO 9002 and product range. When the customer has developed a greater understanding of the Pirtek product range concentrate on promoting the full range of products available rather than focusing on selling the breakdown service.

INSTRUCTION PERIOD Module L: Conducting a Service Call - 1

Module K: Prospecting for Business - 2

OBJECTIVES At the end of this module the trainee will be able to: > Assess the new environment for safety hazards and implement control measures > Assess the hose for repair or replacement Assemble the appropriate replacement hose and install it > Clean the repair site

Operations Maintain CRM

Key Points Become familiar with the products and services that your active customers previously purchased Re-establish contact with these customers and introduce the latest services and products available through Pirtek Note relevant information on the XDA/Orbit, such as change of customer contact or address. Any contact names obtained shall be Christian and surname. For instruction refer to CRM training guide.

Operations Assess the new environment

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19

INDUCTION TRAINING CONTINUED

Key Points When entering a new environment, always assess the surroundings in the environment, look for hazards and conduct a thorough risk assessment before commencing any work. Note any potentially dangerous situations or machinery When working on construction machinery or equipment, ensure that all levers, arms, tines, pallets and buckets have been secured and lowered completely to the ground Ensure all machinery is shut down and de-pressurised before disconnecting hoses

Determine the type of hose and the type of fittings Ascertain the application, pressure and medium Where this information is unknown, obtain clients permission to cut the hose in half and inspect the construction of the hose

Measure the internal diameter of the hose fitting with a pair of vernier calipers to ascertain the size of the ends

Operations Select the appropriate replacement hose

Key Points Lay the damaged hose on ground and lay a length of replacement hose alongside to ascertain overall length of required hose. Note hose must be measured in a straight line and never measure around a curve or bend Lay the fittings at the end of the hose length with one fitting at the hose length and the other corresponding to the shoulder of the first fitting to mark off the hose before cutting Operations Cut the replacement hose Key Points Cut the replacement hose to length using the cut off saw ensuring that you do not drag the hose through the saw but hit the blade with the hose in short sharp motions Insert the ferrule onto the end of the hose, ensuring it is pressed firmly home Very lightly lubricate the hose tails before inserting into the hose

Ensure any moving vehicle is secured

Do not park your vehicle in the way of other mobile equipment

Operations Assess the hose for repair or replacement

Key Points Establish location of the hose

Establish start and end point of hose Establish access to hose Conduct STAMPED analysis to determine: S ize of the hose T emperature under which the hose operates A pplication the hose is to be used for M edium flowing through the hose P ressure the hose will bear E nds and connections to be used on the hose D elivery date due

Operations Prepare the crimper

Key Points Remove previous dies from crimper Insert the correct size dies in the crimper, ensuring die size is checked on the crimping chart supplied Operations Crimp the hose

Module L: Conducting a Service Call - 2 Key Points

Before disconnecting the hose, ensure the pressure has been relieved from the machine. Remove hose. When removing multiple hoses for replacement, either remove hoses one by one, remake and refit. Alternatively, if access does not permit this operation and multiple hoses need to be removed at the same time, ensure that each hose that is removed is identified and numbered against the port that it is to be refitted. A good way to do this is to use coloured cable ties. For example: Hose 1 and port 1 should have 1 x coloured cable tie attached to each. Port 2 and hose 2 should have 2 x coloured cable ties, port 3 and hose 3 should have 3 x cable ties etc etc. Performing this operation will ensure that all the refitted hoses are fitted back to the correct ports on the machine or application.

Key Points Use the procedure outlined in Module I

Operations Measure the hose

Key Points Before the hose is reconnected, ensure the newly assembled hose is measured and the size of the measurement is recorded

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20

PIRTEK INDUCTION 10 DAY TRAINING PROGRAMME

Operations Reconnect the new hose

Key Points Where necessary, always secure hoses with ties

Module L: Conducting a Service Call – 3 Operations Clean the repair site

Key Points Always clean up after the job and replace any components in their respective positions in the Service vehicle, ensuring all tools have been retrieved

Operations Conduct a pressure test

Key Points Always where possible do a pressure check on the hose to make sure there are no leaks and the hose is routed properly. If the machine cannot be tested due to the operator not being present, ensure that you notify the customer that the machine has not been tested and return at a convenient time to conduct the test.

Operations Promote the Company

Key Points Where applicable hand out Pirtek promotional material to the relevant client staff Inform the client staff of the range of Pirtek products and services and try to ascertain the extent and location etc. of future work from the client that may be expected

Points to ensure: Always check the specific application that the hose is supplying, such as a quick hitch.

Check that the quick hitch operation works correctly and open and closes in the correct manner. Make sure that the hoses have not been crossed on refitting. If the hoses have been crossed then this could mean that the quick hitch will open when it is supposed to be closed and close when it is supposed to be open. This could result in the bucket dropping from the quick hitch and could endanger the health, safety and welfare of the operator or others around him.

Operations Maintaining service standards

Key Points Once assigned a job, stay on the job until it is completed and ensure the client is kept informed of developments on the job Only leave the job in special circumstances, where a special fitting needs to be ordered or made in the workshop

Note: Never operate the machine yourself to test the hose, always ensure that a trained operative tests the machine.

In these instances seek approval from the client and inform the depot of the situation

Operations Complete the Paperwork

Where a hose cannot be replaced in the field, radio back to workshop the size and length of hose and the dash numbers of fittings to be attached to the hose in order for the workshop staff to make up the hose assembly Return to the workshop and collect the newly made hose. Immediately return directly to the job and fit the hose. Do not commence new job unless the new hose is not available.

Key Points If a manual works order has been raised ensure the customer is supplied the second copy of the work order Always obtain an order number and contact name from the client

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INDUCTION TRAINING CONTINUED

INSTRUCTION PERIOD Module M: Tagging a Hose Assembly - 1

OBJECTIVES At the end of this module the trainee will be able to: > Understand how to apply the Pirtek Tagging System > Use the Assembly Code Number Chart to identify the code number to be used on the Tag > Understand and be able to complete all required sections of the Tag Module N: System design safety

Module M: Tagging a Hose Assembly – 2

What is to be done?

How is it done?

Points to ensure

Using a Permanent Marking Pen fill in the boxes on the Tag in the manner described below

Ensure each hose assembly fitted has a separate Tag

Complete Identification Tag

Using the “Assembly Code Number” chart identify the part number of the hose and record the related Code Number of the hose and the hose size Record the Pirtek Product Number as specified in the Pirtek Product Catalogue for the fitting attached to one end of the hose

Complete the box titled “HOSE”

Complete the box titled “A”

Record the Pirtek Product Number as specified in the Pirtek Product. Catalogue for the fitting attached to the opposite end of the hose

Complete the box titled “B”

Complete the box titled “DIM”

Record the overall length of the hose in millimetres

Note: do not use decimal points

Where a survey is being conducted and the hose being surveyed is not a Pirtek hose place an “X” in this box and tag the hose

Complete the box titled “MONTH”

Record the current month

Hold the assembly so that you can look along the length of the hose positioned to 0 degrees

Record the rotation angle of fittings in degrees

If the angle is not given then the elbows are

Measure the angle between the vertical and the one nearest to you in a clockwise direction. The relationship can then be recorded from 0°to 360° in the blank box next to the “MONTH” box

Record your personal Pirtek ID number in the blank box next to the box above

Record your own ID number

Complete the box titled “YEAR”

Record the current year

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