AURTTD002_Student_Assessment____Theory_v1.1_BR_1.1.docx

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Feb 20, 2024

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Entered on Training Plan Moderation Student No . _0003001767 Student Name _RONGHAO ZHANG Name RONGHAO ZHANG Imagine Education Student Assessment Cover Sheet Student Declaration I declare that this assessment is my own work and where my work is supported by documents from my workplace placement/employer permission has been granted. Note: Filling out this coversheet as part of an electronic submission and approving the above information will operate in the same way as physically signing this cover sheet. Student name or signature: Office Use Only Date/s Received: / / / / / / Date/s Assessed: / / / / / / Result of Assessment: Course Code AUR30620 Course Name Certificate III in Light Vehicle Mechanical Technology Unit Code AURTTD002 Unit Name Inspect and service steering systems Due Date: Assessment Name Automotive Portfolio Part A: Short answer questions

Note for Assessors: Filling out the above Office Use Only section as part of an electronic submission will operate in the same way as physically signing this cover sheet. If not physically signed, Assessor must print their name in signature box

Imagine Education Assessment Questions Part A Course Code and Name: AUR30620 Certificate III in Light Vehicle Mechanical Technology Unit Code: AURTTD002 Unit Title: Inspect and service steering systems For this assessment, you are required to answer all of the questions. You are permitted to research the answers by reading the learner guide, textbooks, theory notes and accessing the internet. If more room is needed label each task with the question number and use headings or dot points to make your work clear for your trainer and assessor. Please follow the Referencing Guide contained on your Course handbook. Please attach a student assessment cover sheet to each unit submission. You must complete the cover sheet in full detail. 1. Where can you find the information listed in the table below? Item Location Three (3) examples Content Three (3) examples Workplace procedures diagnosing and repairing of steering systems. • Reception desk • Supervisors area • Google Safe work Australia • induction • safety procedures • all incident/hazard report Manufacturer specifications related to steering systems. ● Owner manual ● Manufactu rer Website ● Repair manual of the vehicle 1. testing step 2. servis information 3. vehicle parts

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2. What methods can you use to locate information from the customer required for the inspection and service of the steering system? List three (3). • referring to the repair order • asking the customer or referring to any customer correspondence • discussing with the Manager or supervisor 3. Describe workplace procedures required to inspect and service the steering system. List two (2) for each in the table below. Establish serviceability of tools and equipment. ● Visual examination damage ● Physical where practical examination of serviceability, Location and accessibility of required tools and equipment Documentation procedures ● Qualification (full understanding) of fault conditions ● Accurate recording of fault description 4. Describe the housekeeping procedures required when inspecting and servicing the steering system. List two (2) for each in the table below. Tools and equipment procedures Identify, select, and prepare tools, equipment required to support the diagnosis process, Electronic diagnosis equipment firmware is current and up to date with records of update kept with equipment. Storage of equipment procedures Ensuring tools and equipment are in good working order and are easily accessible, All tools and equipment are to be kept in a secure and correct location Identification, tagging and isolation of faulty equipment procedures tagging and isolation of faulty equipment procedures: Access to fault reporting tags and information required describing nature of equipment fault, Supervisory staff to be alerted to the faulty equipment and a record kept. Safe disposal of excess material procedures Excess material must be disposed of in a safe and secure manner, with regards to environmental requirements, Records of material disposal to be kept and receipts from disposal services kept with management.

Recycling procedures Recyclable material to be placed in designated secure containers, Recycled material records to be kept in a central location for audit procedures.

5. Describe workplace health and safety and occupational health and safety requirements and procedures related to inspecting and servicing steering systems, in the table below. List three (3) for each. Using specialised tools and equipment Visual examination for damage, physical where practical examination of serviceability, Location and accessibility of required tools and equipment , Calibration certificate current. Using appropriate personal protective equipment (PPE) Ensure availability of appropriate PPE equipment, Ensure PPE is in good order and serviceable, Never use PPE equipment for anything other than its purpose. Isolating and stabilising vehicles or machines Ensure vehicles are stabilized on Jack Stands when attempting to inspect and service steering systems, When using vehicle hoists ensure instructions for use are followed, Ensure vehicle is stable and secure on both Stands and Hoist before servicing steering system’s. 6. Describe the environmental requirements and procedures for trapping, storing and disposing of fluids released during servicing operations, listed in the table below. Answer using 20-40 words for each. Acti on Environmental Requirements and Procedures Trapping Ensure mechanical/physical oil dams and barriers to contain any fluid spills are in place, Ensure suitable spill and drip pans and transfer equipment is available for fluids and oils and in good order , Always have “kitty litter” and spill kits available for oils and fluids in case of spills. Storing Hydraulic oils and fluids must only be stored in recommended containers, Oils and fluids must only be stored indoors and in a clean and dry environment, Do not store near heat or steam sources. Disposing Oils and fluids must only be disposed of with certified disposal tracking systems, Never dispose of oils or fluids in or near a water source, Ensure oils and fluids are stored in sealed containers.

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7. Describe and identify the function, and basic operation of the steering systems, listed in the table below. Write your answers using 50 – 100 words for each. Manual steering Manual steering comes in 2 basic types, Steering Rack steering system, In this type uses a rack and pinion, with the pinion moving in response to the steering wheel movement, then moving the rack left or right, Steering box steering system. In this type known as a worm and nut type works through a more complex linkage to move the steering in response to the steering wheel movement. Electric power assisted (EPS) EPS systems have variable power assist, which provides more assistance at lower vehicle speeds and less assistance at higher speeds, The EPS electronic control unit (ECU) calculates the assisting power needed based on the torque being applied to the steering wheel by the driver, the steering wheel position and the vehicle’s speed, The EPS motor rotates a steering gear with an applied force that reduces the torque required from the driver. Hydraulic power assisted steering In this type of power assisted steering system uses a hydraulic ram which is typically used on 4WD vehicles, The Ram is fixed to the axle and the steering linkage to provide assistance in steering the vehicle, Hydraulic fluid is pressurised by a pump working from the engine to provide pressurised fluid to the ram. Full hydraulic steering In this type of power steering system hydraulic force is used to multiply the steering input force in order to smooth out the steering of the front wheels, This hydraulic force is generated by a series of components that includes hydraulic cylinder, rotating hydraulic pump, hydraulic lines, highly compressed hydraulic fluid and a coupling mechanism that can couple this hydraulic system with steering rack. 8. Describe the function of major steering components, listed in the table below. Answer using 20 – 50 words for each. Steering Wheel The steering wheel allows the driver to apply the required effort to the steering gear and control the angle of the steered wheels in the required direction Steering Column The column is fitted between the steering wheel and the steering gear, The column is a collapsible shaft that transfers the steering effort from the driver to the steering gear Steering Gear/Rack The steering gear/box converts the effort from the driver to the steered wheels directing the vehicle in the required direction Steering Gear Idler arm Used in a steering box type system, the idler arm is fitted to the

vehicle frame and the main linkage on the passenger side of the vehicle. The arm is used to transfer the effort to the passenger side wheel. Steering coupling joints The coupling joints served 2 purposes, Absorbs some of the vibration created by normal vehicle operations, Allows for slight variation in the alignment of the column and steering rack/gear

Power steering hoses There are two main power steering hoses, the high side and the low side. Both are attached to the rack and pinion with threaded brass fittings. Power steering pump The power steering pump is turned by the accessory drive belt or serpentine belt to develop fluid pressure in the high side power steering hose to the input side of the power steering control valve. 9. Name the components of the steering column image in the table below 1.Upper steering column section 6. Steering gear 2. Instrument panel 7. Intermediate shaft 3. Lower steering main shaft 8. Lower steering column tube 4. Coupling assembly 9. Mounting bracket 5.Universal joint

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10. Name the components of the rack and pinion image in the table below 1.Mounting bracket 4. Rack 2 . Pinion 5. Tie-rod 3. Adjuster mechanism 6. Tie-rod end 11. Describe the types of lubricants and hydraulic fluids that are used in systems using steering racks and systems using steering gears. Write your answer using 15 – 30 words. Description of the types of lubricants and hydraulic fluids that are used in systems using steering racks and systems using steering gears. Hydraulic fluids are used extensively in systems using steering racks, whereas oils are used in systems using steering gears. 12. What kind of lubricant is used in steering box systems? Write your answer using 15 – 30 words. ● Lubricant used in steering box systems. Steering box systems use oil to lubricate the ball and worm components in the steering box and should be between 80W and 90W gear oil. 13. What are the two (2) different types of power steering rack hydraulic fluids. ● mineral-oil or synthetic oil of some type, blended with additives to suppress foaming, prevent corrosion and improve lubrication in the power steering pump and steering gear.

14. Describe the procedures for inspecting steering systems, listed in the table below. List three (3) procedures for each.

Component wear analysis ● Measure movement, steering-wheel travel before the front wheel begins to move. ● Check for abnormal tyre wear and/or vague or poor responsive steering reaction. ● All components are required to have operating tolerance which should be determined from the manufacturer’s standards. Oil and fluid leaks ● Inspection for fluid leaks must take place where there are signs of dampness around joint and system unions. ● Assessment of leaks must require the engine to be running and at normal operation temperature. ● Operate the steering from full lock to lock and inspect for leaks. Physical damage ● Initial signs of physical damage must be of the wheels, and then signs of damage and/or abnormal tyre wear. ● Due to the nature and use/location of steering gear, it is exposed to impact damage from vehicle usage. ● Before any assessment of the steering component serviceability, a damage assessment of all linkages and wheels must be made 15. Describe service and adjustment procedures for the items listed in the table below. Write your answer using 50 – 100 words for each Adjusting and replenishing oil and fluid levels in a steering system. ● Steering system services must take place in accordance with the manufacturer’s recommendation or following the operators concerns of steering related concerns or problems. ● Adjustments and servicing are generally wheel alignment, wheel bearings and the testing for abnormal wear. ● Oil and fluid levels would be checked and replenished during regular services or following inspection/repair procedures Lubricating components in a steering system ● Steering gear systems utilise a dipstick in the oil reservoir cap to determine the correct level of the oil; replenishing the oil must never exceed the maximum level on the dipstick ● Gear oil level in a steering gear is determined by removing the level plug on the top of the steering box and adjusting the level to the bottom of the plug thread with the recommended oil.

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J:\VET\Automotive\AUR30620 - Cert III Lig Vehicle Mech Tech\AURD002\STUDENT ASSESSMENT GUIDE\ AURTTD002 16. Describe five (5) procedures for post-service testing of a serviced steering system. Post testing MUST be completed after every repair or service of the steering system, Initial testing must be a static one, Inspecting the quality and security of the repairs and /service completed, Review every aspect of the work completed for security, Always complete a wheel alignment procedure to ensure correct alignment, Only complete a road test after successful confirmation of the static inspection.

J:\VET\Automotive\AUR30620 - Cert III Lig Vehicle Mech Tech\AURD002\STUDENT ASSESSMENT GUIDE\ AURTTD002