AURTTF002 WRITTEN ASSESSMENT ANAS IJAZ 20220490

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Cambridge International College, Australia *

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Feb 20, 2024

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AURTTF002 Inspect and service diesel fuel injection systems Assessment 1 – Questioning – Written Assessment Student Name Anas ijaz Student ID Number 20220490 Unit Start Date 01/04/2023 Unit End Date 31/04/2023 Assessment Due Date 20/04/2023 Date Submitted 19/04/2023 This cover sheet is to be completed by the student and assessor and used as a record to determine student competency in this assessment task The assessment process and tasks were fully explained. Yes / No I am aware of which evidence will be collected and how. Yes / No I am aware of my right to appeal an assessment decision. Yes / No I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their website at (Insert Website Link) Yes / No I have discussed any additional educational support or reasonable adjustments I require in order to undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link) Yes / No I have access to all required resources? Yes / No Cheating & Plagiarism Declaration Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit of competency except where the work has been correctly acknowledged. NOTE: Student must sign this prior to submitting their assessments to the assessor Signature Anas ijaz Date : 19/04/2023 Assessment Results Satisfactory or Not Yet Satisfactory (Please circle the assessment result for this task) Feedback to Student - Please provide general feedback on the Student’s performance Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 1 of 36
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 2 of 36 AURTTF002 Inspect and service diesel fuel injection systems Student Declaration: - I verify that the work completed is my own and that I was adequately informed of the assessment process prior to commencing this assessment task. Assessor Declaration: - I verify that I have adequately explained and negotiated the assessment tasks with the student prior to commencing assessment. Student Name: anas ijaz Assessor’s Name: Student Signature Anas ijaz Date: 19/04/2023 Assessor Signature Date Student Guide for Written Knowledge Assessment Overview of Assessment This is a written assessment task you will be assess on your knowledge of inspect and service diesel fuel injection system. The topics that will be covered in the assessment are: 1. Prepare to inspect and service diesel fuel injection system 2. Inspect diesel fuel injection system 3. Service diesel fuel injection system 4. Complete work processes This assessment will ensure that the elements, performance criteria, performance evidence and knowledge evidence required, and conditions are adhered to demonstrate competency in this unit assessment task. Read the assessment carefully before commencing. Your Assessor will use the assessment criteria in this document and will provide feedback / comment. You MUST answer all the questions in the assessment tasks in your own words and own handwriting. This is an “Open Book” assessment, and students can use the resources listed in the “Resources Required” section below. Task/s to be assessed To complete this written assessment, you will need to answer the 66 questions comprising of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions. Time allowed On average, the Assessment should take 2 – 4 hours to complete. Location This theory assessment will be completed in a classroom under the supervision of a trainer/assessor. Decision making rules To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer all questions. If a student achieves less than 100%, they can reattempt the assessment after further study has taken place. Students who cannot achieve a minimum of 100% you
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 3 of 36
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 4 of 36 AURTTF002 Inspect and service diesel fuel injection systems will not have satisfactorily completed this assessment Your assessor will be looking for the following in this assessment task: - Work health and safety (WHS) and occupational health and safety (OHS) requirements relating to inspecting and servicing diesel fuel injection systems, including procedures for: o Working with high pressure diesel fuel systems o Working with high voltage diesel fuel injectors o Working with stored fuel pressures o Engine start-up and shut-down Environmental requirements, including procedures for trapping, storing and disposing of fluids released from fuel systems Application, purpose and operation of air filter and air intake housing and ducting Identification and function of mechanically controlled diesel fuel injection system and components, including: o Types and applications of fuels, including diesel and biofuels o Fuel tank and lines o Fuel filters and sedimenter filters o Fuel supply pumps o Injection pumps, including: In-line Rotary o Injector pipes o Injectors o Overflow or leak-off pipes Identification and function of electronic diesel fuel injection systems and common rail fuel systems and components, including: o Fuel tank and lines o Fuel filters and sedimenter filter o Fuel supply pumps o Injection pumps o Pressure and injector pipes o Fuel rail o Injectors o Overflow or leak-off pipes o Electronic control unit and sensors Inspection procedures for diesel fuel injection systems, including procedures relating to leaks, damaged piping and sedimentary sight glasses Service and adjustment procedures for diesel fuel injection systems, including: o Servicing sedimenter filter o Replacing fuel filter o Bleeding fuel system as required o Servicing air filter and air intake housing and ducting
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 5 of 36 o Engine speed adjustments as required and operational testing Post-service testing procedures for diesel fuel injection system.
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 6 of 36 AURTTF002 Inspect and service diesel fuel injection systems Assessment conditions Assessors MUST satisfy NVR/AQTF assessor requirements. Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting. Assessment MUST include direct observation of tasks. Where assessment of competency includes third-party evidence, individuals MUST provide evidence that links them to the diesel fuel injection systems that they have worked on, e.g. repair orders. Assessors MUST verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application. The following resources MUST be made available: Automotive repair workplace or simulated workplace Workplace instructions Manufacturer diesel fuel injection system specifications Two different vehicles or machinery with diesel fuel injection systems requiring servicing Tools, equipment and materials appropriate for inspecting and servicing diesel fuel injection systems. Resources required Learning Resources available to students include: Automotive Technology (A System Approach) 6 th Edition – Chapters 5, 6, 7, 28 Websites – - https://www.racq.com.au/cars-and-driving/cars/owning-and- maintaining-a-car/car- maintenance/diesel-injector-cleaning - http://www.foxwell.com.au/diagnosing-crd-faults-with-a-pressure-tester/ - https://www.waybuilder.net/free- ed/Courses/15%20Transportation/AutomotiveSyste ms.asp - http://www.offroadaussie.com/2013/02/how-does-a-4wd-snorkel-work/ - https://en.wikipedia.org/wiki/Common_rai l - https://en.wikipedia.org/wiki/Glowplug - http://www.cnctechnw.com/PDF/BoschDistPump.pdf Trainer Handouts Results/Re- assessment The Assessor will grad`e the assessment and record the result on the front page of this document (S) – Satisfactory if all observable behaviours are correct and (NS) not satisfactory if any areas are left incorrect Feedback will be provided on either result Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss the area of the non-compliant observable behaviour and an opportunity given for re- assessment. This may be through direct observation or a different method of assessment e.g. verbal/oral questioning, problem solving exercise. If the outcome is again not satisfactory the student result will be deemed
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 7 of 36 (NYC) not yet competent. Additional feedback will be given, and a time agreed upon for further assessment after additional training and skills practice has taken place, this information will be recorded, dated and signed in the re-assessment area on the
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 8 of 36 AURTTF002 Inspect and service diesel fuel injection systems last page of this document Where all the assessment tasks have been graded (S) Satisfactory, the student will be deemed C – Competent for the practical component and the result recorded and signed in the area indicated on the last page of this document Reasonable Adjustment If the participant is unable to undertake the written assessment as designed, an interview (verbal questioning) may be used as an alternate approach.
Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 9 of 36 AURTTF002 Inspect and service diesel fuel injection systems Assessment 1 – Questioning Written Assessment 1. Safety must always be considered a high priority when working on ‘Common Rail’ fuel systems. Why? The operation of common rail fuel system is at high pressure. If there is high pressure fuel, there is always risk for death or fatal injury. Removing an injector or starting of engine for the identification of spray pattern is always dangerous. There are some electronic diesel injectors which operates on high voltage i.e. 150 volts 2. Some electronic diesel fuel injectors work on high voltage. They can produce around 120 – 150 volts and 20amp of current. What should always be off and why? There are some electronic diesel injectors which operates on very high voltage i.e. 150 volts and there is always risk of high electric shock. EI (Electronic Injectors) are generally calibrated individually with the engine management and they should be refitted with the original position 3. Before loosening or disconnecting fuel lines, all pressure in the system must be released. Why? Before beginning of any sorts of process on the system, pressure should be released in the fuel lines and they should include fuel pump, fuel injector and fuel lines. 4. What is a ‘Glow plug’? It is a type of heating appliance which are used to support ignition of diesel engine. During cold weather, it will be very difficult for diesel engines to start as mass of cylinder gets blocked and all the heat coming from compression Multiple Choice question. Select the correct answer.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 10 of 36 5. To stop the engine fitted with a distributor-type pump: A. The throttle valve is released. B. A cut-off solenoid is used. C. The no-fuel position is selected.
AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 11 of 36 D. The fuel rail is moved. 6. How should waste fuel from a diesel fuel system be stored and disposed? Waste oil should be collected in a secure way, properly labelled tanks or drums should be stored in under covered area. If they are stored in double skinned tank then there will be no necessity for bunding, but if they are stored in single skinned tank they should be bunded. EPA approved contractor should be appointed for the removal of waste oil for the purpose of recycling, disposal and treatment.
1 1 Clip 2 2 Element 3 3 Disc 4 4 Sump 5 5 Oil bath 6 6 Gasket 7 7 Mesh element in body AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 12 of 36 7. When handling, trapping, storing and disposing of diesel fuel new or waste fuel, which document should you use to find this information? 8. Name the seven [7] parts of a diesel air cleaner assembly below. Multiple Choice question. Select the correct answer. 9. How many air filters can a Diesel engine have? A. 1 . B. 2. C. 3. D. 4. Multiple Choice question. Select the correct answer. 10. Some off-road vehicles are likely to have what type of air cleaners? A. Pre-cleaner and a Main cleaner. B. Post-cleaner and Main cleaner.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 13 of 36 C. Pre-cleaner and Post-cleaner.
AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 14 of 36 D. Main cleaner and Post-cleaner. 11. The air intake on some off-road vehicles are mounted externally and raised almost to the height of the vehicle. Why? For the reduction of chance of water which enters inside the engine while crossing water. Amount of dust which are entering inside the system are reduced with the help of higher air intake 12. Why is a cyclone filter called a cyclone filter? It is a method which assist for the removal of particulates from gas, liquid stream or air without using filters from vortex separation. 13. How does the cyclone filter operate? Cyclone separators refers to centrifugal separators where particles due to their mass are pushed to outer edges due to the presence of centrifugal force, but with the supply of dirty air. Here, chamber is fed with the dirty flue gas. Spiral vortex is created by chamber and it is similar to tornado. These particles are present in air and are compelled to outer edges and they leave separator with the assist of collection device which are fitted in the 14. Name two (2) types of fuels that a Diesel engine can use? 1 a. Biodiesel 2 b. Petroleum diesel 15. What are the five (5) properties of fuel for diesel engines? Explain each one in detail. 1 Heat Value: It is measured with the help of calorimeter for the determination of amount of energy provided by
AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 15 of 36 fuel while burning 1 Ignition Quality/Cetane Rating: It is regarded as the measure of ignition quality of fuel. The position where
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 16 of 36 AURTTF002 Inspect and service diesel fuel injection systems diesel fuel is ignites and it helps in the way they burns influences starting of engine. 2 Viscosity: It is a simple measurement of resistance to flow. They are decreased when temperature is increased 3 Sulfur Content: It consist of components like rings, pistons, valves, cylinders 4 Water and sediment content: They can cause damage or rusting to fuel system components
1 1 Air cleaner 2 2 Injector 3 3 Intake manifold 4 4 Supply line 5 5 Sedimenter 6 6 Fuel tank 7 7 Return line 8 8 Injection Pipe 9 9 Fuel filter 10 10 Injection pump 11 11 Air intake 12 12 Baffle 13 13 Air silencer AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 17 of 36 16. What is ‘Biodiesel’ made from? It is defined as ‘diesel fuel which are gained from esterification of oil which is derived from animals and plants, according to fuel standard determination 2003 for Australia. They are generally made from fats of animals, vegetable oil and used cooking oil. 17. Name the thirteen [13] components of the mechanically controlled diesel fuel system below. 18. The purpose of the fuel tank is?
AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 18 of 36 19. The purpose of the supply and return fuel lines is? The objective of fuel supply system is they assist for storage and filtering of required fuel and to provide fuelinjection system with fuel in different functioning conditions. In some cases, the return fuel flow are also cooled.
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AURTTF002 Inspect and service diesel fuel injection systems 20. Why is filtration important in a diesel fuel system? In-line fuel system helps for stopping large and damaging contaminants like sediment from fuel tank, rust which are entering into the fuel system. They are important as they helps for the protection of fuel pump & injectors not only from abrasive particles. 21. What type of filters are used in a diesel fuel system? Primary and secondary filters are used in diesel fuel system 22. How is water filtered from a diesel fuel system? Filtration of water is done with the help of fuel water separator filter which is placed in the engine fuel system. The filtration system is available in the separators; hydrophobic barrier media like silicone treated cellulose is one of the common filtration media. 23. What is a sedimenter? They refers to fuel sedimenter which operates on the concept of density and they separates out water from the diesel with the aim that diesel is not passed to injectors. 24. Explain how a sedimenter operates? Water is separated from the diesel fuel with the help of fuel sedimenter. Specific gravity difference between water & diesel fuel is used by them for the separation of water before fuel is entered in the injection pump. The sliding portion present inside the injection pump is lubricated with the help of fuel and they are important to drain water from fuel as lubrication is less if fuel are mixed with water
AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 13 of 36
AURTTF002 Inspect and service diesel fuel injection systems 25. What is the purpose of a feed or supply pump? They are used for the delivery of fuel from the fuel tank to fuel injection pump with the help of fuel filter. They are attached to injection pump and are driven with the help of camshaft. Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 14 of 36
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AURTTF002 Inspect and service diesel fuel injection systems delivery valve holder suction chamber barrel fuel control rack camshaft roller pin drive coupler plunger spring 1 control sleeve 26. What type of pumps are used for fuel feed or supply? They are diaphragm and plunger type mechanical pumps. 27. Name the eleven [11] main parts of an in-line injection pump 1 delivery pipe 11 control rack 28. What is meant by the effective stroke of a pump plunger? It is a type of stroke from the time of top of plunger which covers inlet port until spill port is covered by helix. 29. How is the quantity of fuel that is delivered by a pumping element of an in-line pump controlled? It is controlled with the help of control rod, constant speed of engine present in an inline pump system. They Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 15 of 36
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 16 of 36 AURTTF002 Inspect and service diesel fuel injection systems are completed by the help of driver releasing or depressing the accelerator pedal which lies between idle & maximum speed.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 17 of 36 AURTTF002 Inspect and service diesel fuel injection systems 30. What is the purpose of a delivery valve on an in-line pump? When the required amount of fuel is delivered by the help of pump, fuel pressure present at the outlet of the pump falls. The major objective of delivery value is they helps in maintaining pressure present in fuel delivery line which is present below the nozzle closing pressure. 31. What is the function of the control rod of an in-line pump? To hold constant speed of engine, controlling rod present in an inline pump system which are controlled or moved from injected fuel quality. 32. What is an ‘axial-type distributor injector pump? In ‘axial-type distributor injector pump’ fuels are supplied from the vane type pump. The main task of central piston is to generate pressure and distribute them to the individual engine cylinder which runs on the cam plate. 33. Name the nine [9] parts of an axial-type distributor injector pump below.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 18 of 36 AURTTF002 Inspect and service diesel fuel injection systems 1 1 Control lever 2 2 Top cover 3 3 Overflow pipe 4 4 Fuel cut off solenoid 5 5 Delivery valves to injectors 6 6 Distributor 7 7 Timing device 8 8 Housing 9 9 Mounting flange
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 19 of 36 AURTTF002 Inspect and service diesel fuel injection systems 34. Explain briefly what the plunger of an axial-type distributor pump does during a pumping stroke? Plunger consist of vertical grooves which are equal to number of cylinders present in the engine. They works as the fuel inlet passage to the barrel during inlet stroke of the piston. 35. What produces movement of the plunger in an axial-type distributor pump? Rotational motion present in the drive shaft are moved to the plunger with the help of roller ring assembly, yoke assembly and cam plate 36. Name the eight [8] parts of a mechanical radial-type injection pump. 1 1 Pressure control valve 2 2 Governor assembly 3 3 Overflow restriction 4 4 Distributor head with high 5 pressure pump 6 5 Vane type fuel supply pump 7 6 timing device 8 7 Cam plates 37. Explain the low-pressure phase of a mechanical radial-type injection pump. They includes fuel tank, electric supply pump present in the fuel tank and filter or filter sedimenter. They are regarded as low pressure line for the supply for fuel to high pressure pump and low pressure pump in order to return fuel to the tank.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 20 of 36 AURTTF002 Inspect and service diesel fuel injection systems They runs continuously in order to supply fuel to high pressure pump and consists of permanent magnet electric motor.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 21 of 36 38. Explain the high-pressure phase of a mechanical radial-type injection pump. They includes high pressure injection pump, common fuel rail, high pressure fuel lines and injectors. They are used for the generation of high fuel pressure and for the delivery to the common rail. They donot have any timing or functions but they produces high pressure. 39. To ensure the fuel system is sealed and operates correctly at all times, fuel pipes and hoses must be in good condition. Explain why? Fuel delivery testing make sure that proper fuel pressure and volume are present under all possible operation situation. 40. Name the nine [9] parts of an injector.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 22 of 36 1 1 Leak off connection 2 2 Cap nut 3 3 Spring 4 4 Adjusting nut 5 5 Adaptor 6 6 Nozzle holder 7 7 Spindle 8 8 Nozzle nut 9 9 Nozzle
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1 Single hole 2 Conical end single hole 3 multi hole 4 long stem 5 Pintle 6 Delay AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 23 of 36 41. Name the six [6] following injector nozzles types. 42. In point form, describe the operation of a hydraulically actuated mechanical diesel fuel injector. They consists of injector body with needle control chamber, nozzle chamber and nozzle outlet which opens in the nozzle chamber. Fuel present within the injector are pressurized hydraulically during every injection cycle. Needle valve are placed reciprocate in the nozzle chamber which is between open position where nozzle outlet is open and are closed while nozzle outlet are closed.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 24 of 36 43. What are leak-off or overflow pipes and what do they do?
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 25 of 36 AURTTF002 Inspect and service diesel fuel injection systems They are utilized for returning excess fuel after injection of fuel in the diesel engine
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 26 of 36 AURTTF002 Inspect and service diesel fuel injection systems 44. Name the fourteen [14] parts of a common-rail injection pump. 1 1 Electrical connection 8 8 Safety valve 2 2 Outlet valve 9 9 Eccentric 3 3 Pumping chamber 10 10 pump shaft 4 4 High pressure fuel 11 11 Drive cam 5 5 Pressure control valve assembly 12 12 Plunger 6 6 Fuel return 13 13 Inlet valve 7 7 Fuel inlet 14 14 Element shut off 45. Explain how the common-rail injection pump operates? Here, fuel are distributed to injectors from high pressure accumulator which is often termed as rail. Rail are
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 27 of 36 fed
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 28 of 36 AURTTF002 Inspect and service diesel fuel injection systems with high pressure fuel pump and pressure present in the rail helps in start and end of signal which activates injector for every cylinder.
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1 Filter 2 ECU 3 Controller 4 Common rail 5 Fuel filter 6 Fuel pressure sensor 7 Jumper lines 8 Gear pump 9 High pressure pump 10 Accumulator 11 Solenoid valve Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 29 of 36 AURTTF002 Inspect and service diesel fuel injection systems 46. Common-rail fuel system uses high pressure fuel lines. Why? They benefits for earlier lower pressure fuel injection by removing fuel as the larger number of smaller droplets which provides high ratio of surface area to volume. 47. What is the purpose of the common-rail in an injection system? They are the type of long metal cylinder which receives fuel from pump and are distributed to the injectors under high pressure. 48. Name the thirteen [13] components of an electronically controlled diesel fuel system.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 30 of 36 AURTTF002 Inspect and service diesel fuel injection systems 12 Injectors 13 Fuel tank
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1 Electrical connection 2 High pressure fuel 3 Feed orifice 4 Control plunger 5 Needle 6 Gallery 7 Control chamber 8 Bleed orifice 9 Ball valve 10 Solenoid windings 11 Fuel return Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 31 of 36 AURTTF002 Inspect and service diesel fuel injection systems 49. Name the eleven [11] parts of a common-rail injector. 50. Name the six [6] parts of Piezo-type injector.
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 32 of 36 AURTTF002 Inspect and service diesel fuel injection systems 1 Fuel inlet 2 Fuel return 3 Piezo stack 4 Hydraulic control plunger 5 Control valve
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 33 of 36 51. Explain the operation of a common-rail injector. Their operation is same as other injectors where needle of nozzle is concerned. They consist of electronic solenoid to trigger injection and when injectors are not injecting, needle are held down against seat in the nozzle with the help of spring force and with fuel pressure. It is done with the help of electronic control unit. 52. Describe the operation of the ‘Piezo Stack’ in a Piezo-type injector. It consist of numerous of crystal like materials which forms ceramic piezo electric discs and these discs are expanded when voltage is applied to stack and contracts when voltage are removed. 53. How is electronic control used in a diesel injection system? They are used for controlling opening and closing of nozzle. Here, signals are converted into mechanical forces with usage of some types of actuator. These actuators can be in the form of electromagnetic solenoids or in the form of active materials like piezoelectric ceramics 54. List eight (8) points where fuel leakage may occur in diesel fuel systems. 55. a. Injector return hoses 56. b. Fuel hoses & clamps (engine compartment) 57. c. Fuel hoses & clamp (fuel tank) 58. d. Pre filter 59. e. Hand primer pump 60. f. Main fuel filter bolt seals 61. g. Delivery valves 60x engines 62. h. Fuel warmer 60x engines 63. i. Fuel injector with hard metal lines
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 34 of 36 Multiple Choice question. Select the correct answer. 64. The fuel filter, fuel lines and various connections should be checked for leaks, with the? A. Ignition on, Engine off. B. Ignition on, Engine on. C. Ignition off, Engine off. D. All answers are incorrect. Multiple Choice question. Select the correct answer. 65. Sedimenters fitted with a sight glass bowl lets you check for? A. Water and deposits. B. Diesel fuel. C. Unleaded petrol. D. Air in the system. 66. How are sedimenters serviced? The warning light present in the instrumental panel will glow when around ½ liter of water is accumulated in the sedimenter. The engine should be shut off if the warning light glows to maintain safety. Here, suitable type of container or drain pan must be used under sedimenter which are placed inside the frame rail which is underneath driver’s side of cab. 67. Explain how a ‘Canister’ fuel filter is serviced? of container or drain pan must be used under sedimenter which are placed inside the frame rail which is underneath driver’s side of cab.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 35 of 36 68. What is the procedure to service is a ‘Disposable’ filter element?
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Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 36 of 36 AURTTF002 Inspect and service diesel fuel injection systems It should be held on top cover with the help of centre bolt Plug present in the bottom must allow filter to be drained before removal of bowl. Once they are removed, bowl should be washed with clean fuel and new filter element should be used
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 37 of 36 69. Why is it necessary to bleed a diesel fuel system? When diesel ran out of fuel, air is sucked by fuel pump with the reaming fuel which are refilled in the engine, so it is necessary to bleed the air out of fuel circuit in order to maintain fuel pressure and to avoid fire. 70. Explain how a mechanically controlled diesel fuel system is bled. a. Loose bleed plug present on the top of filter where pressure side of hand priming pump b. Hand priming pump should be operated until fuel is removed from the bleed plug. c. Same bleeding operation should be performed if there is another filter. d. Now start the engine and bleed each injector pipe in turn. 71. Although not considered part of the fuel system, why is it standard practice to service diesel engine air filters to ensure efficient engine operation? Combustion process depends upon the pistons compressing fuel and air in high pressure and for resultant heal in order to create explosion which are set in train the internal combustion sequence. 72. Explain calibrating in relation to an in-line pump. Calibration consists of replacement of o-rings, oil seals, cleaning and testing with the machine if injection pump is operated properly and they will be adjusted to normal settings
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 38 of 36 Multiple Choice question. Select the correct answer. 73. Which source of information will give you the most detail about inspecting and servicing diesel fuel systems on the vehicle you are working on? A. Workshop manual. B. Owner’s manual. C. Google. D. Textbooks.
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AURTTF002 Inspect and service diesel fuel injection systems Document Name: Student Written Knowledge Assessment – AURTTF002 Created Date: 12 th Aug 2020 Document No: Trinity Institute (Australia) – AURTTF002 Version No: 1.0 Last Modified Date: © Trinity Institute (Australia)| RTO Code: 41310| CRICOS Code: 03556F Page Sequence: Page 39 of 36 74. Why is it very important that the Job Card is completed correctly? They are related to specific job and provides details of time required to perform a piece of work and required materials during such process 75. Consider the various post service checks that you would make on the diesel fuel system? a) Check coolant b) maintenance of diesel engine regularly c) change air, fuel and oil filter if required d) Change oil if required.
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