Mechanical Technology PAT GR 12 2022 (Automotive) Eng

Downloaded from hlayiso.com MECHANICAL TECHNOLOGY (AUTOMOTIVE) GUIDELINES FOR PRACTICAL ASSESSMENT TASKS PAT) GRADE 12 2022 These guidelines consist of 42 pages. Copyright Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 2 DBE/PAT 2022 NSC TABLE OF CONTENTS PAGE 1. INTRODUCTION/BACKGROUND 3 2. TEACHER GUIDELINES 4 2.1 Administration of PAT 4 2.2 Assessment of PAT 4 2.3 Moderation of PAT 4 2.4 Consequences of absence/non-submission of tasks 4 2.5 Declaration of authenticity 5 3. LEARNER GUIDELINES 6 Instructions to the learner 6 4. SPECIALISATION 7 AUTOMOTIVE 7 TASK 1: Compression and cylinder leakage test (COMPULSORY) 9 TASK 2: Gas analysing test 16 TASK 3: Wheel balancing 21 TASK 4: Charging system 25 TASK 5: Fuel pressure test 27 TASK 6: Measuring engine components 30 TASK 7: Computerised diagnostic scanner 36 5. SUMMARY MARK SHEET – TOTALS 39 6. ANNEXURE A 40 7. CONCLUSION 42 Copyright Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 3 DBE/PAT 2022 NSC 1. INTRODUCTION/BACKGROUND The 18 Curriculum and Assessment Policy Statement subjects which contain a practical component all include a practical assessment task (PAT). These subjects are:  AGRICULTURE: Agricultural Management Practices, Agricultural Technology  ARTS: Dance Studies, Design, Dramatic Arts, Music, Visual Arts  SCIENCES: Computer Applications Technology, Information Technology, Technical Sciences, Technical Mathematics  SERVICES: Consumer Studies, Hospitality Studies, Tourism  TECHNOLOGY: Mechanical Technology, Civil Technology, Electrical Technology, and Engineering Graphics and Design A practical assessment task (PAT) mark is a compulsory component of the final promotion mark for all learners offering subjects that have a practical component and counts 25% (100 marks) of the end-of-year examination mark. The PAT is implemented across the first three terms of the school year. This is broken down into different phases or a series of smaller activities that make up the PAT. The PAT allows for learners to be assessed on a regular basis during the school year and it also allows for the assessment of skills that cannot be assessed in a written format, e.g. tests or examinations. It is therefore important that schools ensure that all learners complete the practical assessment tasks within the stipulated period to ensure that learners are resulted at the end of the school year. The planning and execution of the PAT differs from subject to subject. The PAT allows the teacher to directly and systematically observe applied competence. The PAT comprises the application/performance of the knowledge, skills and values particular to that subject and counts 25% of the total promotion/certification mark out of 400 for the subject. The PAT is implemented across the first three terms of the school year. Any profession requires of its members a thorough grounding in both theory and practice and MECHANICAL TECHNOLOGY is no exception. It is emphasised that the goal of the practical assessment task is to produce a skilled learner in each specialisation field. A nation's true wealth is in its manpower and education that should aim to develop the talents of a learner so that he/she can contribute to the well-being of the society by using and developing scientific and technological resources. To prepare a learner in the MECHANICAL TECHNOLOGY specialisation fields, one must focus on the following:  An attitude where the learner can selectively use ideas, gather evidence and facts, to drawing logical conclusions to put them to good use creatively and with imagination;  A capability to express ideas and information clearly by speech, writing, drawing and manufacturing; and  A willingness and capability to accept and exercise responsibility, to make decisions, and to learn by experience. Attributes such as these cannot all be achieved in a classroom. A sound knowledge of engineering sciences is essential to equip the MECHANICAL TECHNOLOGY learner with the necessary practical capabilities for the required processes. Practical training is the application of acquiring essential skills to bridge between trade theory and practice. Practical application in the workshop must therefore be made an interesting and challenging experience to develop the learner physically and mentally. The learner must show his/her initiative, curiosity and persistence in learning. In order to stimulate and develop self-confidence the granting of some degree of responsibility during the practical application is very important. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 4 DBE/PAT 2022 NSC 2. TEACHER GUIDELINES 2.1 Administration of the PAT Teachers are requested to make copies of the different specialisation PAT documents. These documents need to be handed out to the learners at the beginning of the year. The practical assessment task for Grade 12 is externally set, internally assessed and externally moderated. Teachers must attach due dates for the different facets of the PAT (refer to the CAPS document). In this manner, learners can easily assess their progress. When formal assessment takes place it is the responsibility of the teacher to administer assessment. The PAT should be completed within the first three terms. The PAT should be completed under controlled conditions (refer to Mechanical Technology SPECIALISATION: CAPS Grades 10–12). Teachers MUST build a prototype of the task in order to be able to demonstrate to the learners what the final product will look like. It will guide the learners with visual presentation. It provides the teacher with insight into possible challenges regarding machines, equipment or material and what possible manufacturing procedures he/she needs to follow in the workshop in order to complete the PAT. NOTE: The learner has to execute the tasks in practice. The teacher must record reasons, findings, specifications, etc. provided by the learner on the worksheet. Task 6, the worksheet, must be given to the learner as the calculations have to be done. 2.2 Assessment of PAT Frequent and developmental feedback is needed to ensure the necessary guidance and support for the learners. Both formal and informal assessment should be conducted to ensure that the embedded skills are developed. Informal assessment can be conducted only to monitor the progress of the learners. Formal assessment should always be conducted and recorded by the teachers. On completion of each phase in each term, the marks for the completed phase need to be recorded on the school administration system. 2.3 Moderation of PAT The tasks, projects, assessment criteria as well as the mark sheets must be presented to the moderator during moderation of the PAT. The moderator should be able to call on a learner to explain and demonstrate the functions, principles and skills during the moderation process. On completion the moderator will, if necessary, adjust the marks of the group upwards or downwards depending on the decision reached as a result of moderation. Tasks must be clearly marked with the correct initials and surname of each learner. 2.4 Consequences of absence/non-submission of tasks. If a learner's practical assessment task is incomplete or unavailable with a valid reason, the learner may be given three weeks before the commencement of the final end-of-year examination to submit the outstanding task. Should the learner fail to fulfil the outstanding PAT requirement, such a learner will be awarded a zero mark for that PAT component. A learner's results are regarded as incomplete if he/she does not offer any component of the PAT task. He/She will be given another opportunity based on the decision of the head of the assessment body. Should the learner fail to fulfil the outstanding PAT requirement, the marks for these components will be omitted and the final mark for Mechanical Technology will be adjusted for promotion purposes in terms of the completed tasks. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 5 DBE/PAT 2022 NSC 2.5 Declaration of Authenticity NAME OF THE SCHOOL: NAME OF LEARNER: (FULL NAME(S) AND SURNAME) NAME OF TEACHER: I hereby declare that the tasks submitted for assessment is my own, original work and has not been previously submitted for moderation. SIGNATURE OF LEARNER DATE As far as I know, the above declaration by the learner is true and I accept that the work offered is his or her own. SIGNATURE OF TEACHER DATE SCHOOL STAMP Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 6 DBE/PAT 2022 NSC 3. LEARNERS GUIDELINES Instructions to the learners  The practical assessment task (PAT) consists of a compulsory task in Automotive. The compulsory task could be spread over three terms, as set out in this document. (Also see CAPS document.)  All tasks must be completed according to the time frames set out in each of the tasks.  Learners are requested to actively engage in all practical assessment tasks.  Learners who are uncooperative will receive demerits or a zero mark for that particular section of the work.  Learners who act unsafely in the workshop and place other learners in danger, will be given additional corrective tasks to improve their safety awareness.  Your tasks must be fully completed by the end of August 2022 in order to be ready for provincial and/or national moderation.  Your worksheets must to be clearly marked with your name and surname.  At least one phase must be completed each term. The additional compulsory task must be completed during term 1, term 2 or term 3. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 7 DBE/PAT 2022 NSC 4. SPECIALISATION: AUTOMOTIVE (SPECIFIC) Term: 1 to 3 Starting date: January 2022 Completion date: August 2022 INTRODUCTION: This section comprises SEVEN practical tasks TASK 1: Compression and cylinder leakage test is a COMPULSORY TASK Choose any THREE of the SIX given tasks 2–7, namely: TASK 2: Gas analysing test TASK 3: Wheel balancing TASK 4: Charging system TASK 5: Fuel pressure test TASK 6: Measuring engine components TASK 7: Computerised diagnostic scanner NOTE: TASK 1 IS COMPULSORY. EXECUTE ANY THREE OF THE OTHER SIX TASKS GIVEN (TASKS 2–7). NOTE: Number of tasks = 4 (1 + 3) The teacher must explain to the learners which knowledge and skills will be assessed during these tasks as well as the time to complete each task. Activity outcome: ● Learners apply theoretical knowledge in practice with regard to: o Safety, tools, maintenance and systems and control o Correct use of tools and equipment o Use equipment to diagnose faults in the engine, ● These tasks must be done under the supervision of the teacher and the learners should be assessed while performing these tasks. ● The learners should answer questions, record findings and give reasons for certain actions on the worksheet provided while they are performing these tasks. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 8 DBE/PAT 2022 NSC TASK 1 (COMPULSORY) TASK 1: COMPRESSION AND CYLINDER LEAKAGE TESTS ● WORKSHEET 1.1: COMPRESSION AND CYLINDER LEAKAGE TESTS – QUESTIONS o Answer the questions on WORKSHEET 1.1. ● WORKSHEET 1.2: COMPRESSION TEST – PROCEDURE o Perform the tasks as indicated on WORKSHEET 1.2 and record the findings and conclusions on WORKSHEET 1.2. o Use the specification manual to obtain readings for the engine that you are using to conduct the compression test. o Perform a dry and a wet compression test on a four-cylinder, four-stroke petrol engine and record the findings. ● WORKSHEET 1.3: CYLINDER LEAKAGE TEST – PROCEDURE o Perform a cylinder leakage test on a four-cylinder, four-stroke petrol engine and record the findings and conclusions on WORKSHEET 1.3. TASK 2: GAS ANALYSING TEST ● WORKSHEET 2.1: GAS ANALYSING TEST – QUESTIONS o Answer the questions on WORKSHEET 2.1. ● WORKSHEET 2.2: GAS ANALYSING TEST – PROCEDURE o Perform the tasks as indicated on WORKSHEET 2.2. o Use the specification manual to obtain readings for the engine that you are using to conduct the gas analysis test. TASK 3: WHEEL BALANCING ● WORKSHEET 3.1: WHEEL BALANCING – QUESTIONS o Answer the questions on WORKSHEET 3.1. ● WORKSHEET 3.2: WHEEL BALANCING – PROCEDURE o Perform the tasks as indicated on WORKSHEET 3.2. o Use a wheel balancing machine to balance a wheel. TASK 4: CHARGING SYSTEM ● WORKSHEET 4: CHARGING SYSTEM – PROCEDURE o Perform the charging system test procedures on a vehicle and thereafter test the alternator components as on WORKSHEET 4. TASK 5: FUEL PRESSURE TEST ● WORKSHEET 5.1: FUEL PRESSURE TEST – QUESTIONS o Answer the questions on WORKSHEET 5.1. ● WORKSHEET 5.2: FUEL PRESSURE TEST – PROCEDURE o Perform the fuel pressure test procedures on a fuel system and record the findings on WORKSHEET 5.2. TASK 6: ENGINE COMPONENT MEASUREMENT AND CALCULATIONS ● WORKSHEET 6.1: ENGINE COMPONENT MEASUREMENT AND CALCULATIONS – QUESTIONS o Answer the questions on WORKSHEET 6.1. ● WORKSHEET 6.2: ENGINE COMPONENTS MEASUREMENT AND CALCULATIONS – PROCEDURE o Perform the engine components measurement and calculations procedures on an engine and record the findings on WORKSHEET 6.2. TASK 7: COMPUTERISED DIAGNOSTIC SCANNER ● WORKSHEET 7.1: COMPUTERISED DIAGNOSTIC SCANNER – QUESTIONS o Answer the questions on WORKSHEET 7.1. ● WORKSHEET 7.2: COMPUTERISED DIAGNOSTIC SCANNER – PROCEDURE o Perform the computerised diagnostic scanning procedures on a vehicle and record the findings on WORKSHEET 7.2. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 9 DBE/PAT 2022 NSC THE FOLLOWING TASK IS COMPULSORY. TASK 1: COMPRESSION AND CYLINDER LEAKAGE TESTS – QUESTIONS WORKSHEET 1.1 NAME: QUESTIONS MARK TOTAL 1.1.1 Describe THREE differences between the cylinder compression 6 test and the cylinder leakage test. COMPRESSION TEST: CYLINDER LEAKAGE TEST: 1.1.2 Describe FIVE safety precautions that must be adhered to while 5 conducting the compression test. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 10 DBE/PAT 2022 NSC 1.1.3 State FIVE causes of low compression in an engine. 5 1.1.4 State THREE faults that can develop due to low compression in 3 an engine. 1.1.5 Explain the meaning of the expression engine compression. 2 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 11 DBE/PAT 2022 NSC 1.1.6 Name TWO compression tests that can be done on an internal 2 combustion engine. 1.1.7 After which compression test could the reading be higher? 1 1.1.8 Give TWO reasons for the higher compression reading in 2 QUESTION 1.1.7. 1.1.9 State FIVE causes of leakages in the cylinder of an internal 5 combustion engine. TOTAL – Compression and cylinder leakage tests – Questions 31 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 12 DBE/PAT 2022 NSC TASK 1: COMPRESSION TEST – PROCEDURE WORKSHEET 1.2 NAME: DRY COMPRESSION TEST 1.2.1 Conduct a dry compression test. PROCEDURE MARK TOTAL (a) Obtain the compression pressure specification. 1 (b) Start the engine. 1 REASON: (c) Check if engine is at 2 operating temperature. (d) Switch off the engine. 1 (e) Number the spark plug (HT) leads according to the cylinder. 1 (f) Remove the spark plug (HT) leads. 1 REASON: (g) Clean around the spark plugs before removing 2 them. (h) Remove spark plugs. 4 REASON: (i) Remove the air filter. 2 (j) Disable the ignition system; if not, remove HT lead from coil. 1 (k) Disconnect the fuel supply. 1 (l) Fit compression tester on the cylinder. 4 (m) Fully open throttle valve. 4 (n) Crank engine to perform test on each cylinder. 4 1. 2. (o) Record the readings. 4 3. 4. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 13 DBE/PAT 2022 NSC REASON: (p) Compare the readings. 2 TOTAL – Dry compression test – Procedure 35 WET COMPRESSION TEST 1.2.2 Conduct a wet compression test on the cylinder with the lowest reading. PROCEDURE MARK TOTAL (a) Squirt oil into cylinder onto piston. 1 (b) Fit compression tester. 1 (c) Open throttle valve fully. 1 (d) Crank engine 4 to 10 times. 1 (e) Record the readings. 1 REASON: (f) Conclusions after the wet 3 compression test. (g) Replace spark plugs (turn plugs in by hand). 4 (h) Reconnect electrical connections, and HT leads. 1 (i) Reconnect fuel supply. 1 TOTAL – Wet compression test – Procedure 14 TOTAL – Dry compression test – Procedure 35 TOTAL – Wet compression test – Procedure 14 TOTAL – Compression test 49 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 14 DBE/PAT 2022 NSC TASK 1: CYLINDER LEAKAGE TEST – PROCEDURE WORKSHEET 1.3 NAME: CYLINDER LEAKAGE TEST 1.3 Perform the cylinder leakage test on one cylinder. PROCEDURE MARK TOTAL 1.3.1 Turn engine clockwise at front pulley. 1 REASON: 1.3.2 Turn engine until cylinder is on 2 compression stroke. 1.3.3 Turn piston to TDC. 1 1.3.4 Lock the crankshaft. 1 1.3.5 Screw the spark-plug hose adapter into the spark-plug hole. 1 1.3.6 Connect the leakage tester to the compressor. 1 REASON: 1.3.7 Calibrate the leakage 2 tester. 1.3.8 Connect leakage tester to spark-plug hole adapter. 1 1.3.9 Read the percentage 2 leakage. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 15 DBE/PAT 2022 NSC 1.3.10 Check for the cause 8 of leakages. TOTAL – Leakage test – Procedure 20 COMPRESSION AND CYLINDER LEAKAGE TESTS MARK TOTAL MARK SUMMARY TOTAL – Compression and cylinder leakage tests – Questions 31 TOTAL – Compression test – Procedure 49 TOTAL – Cylinder leakage test – Procedure 20 TOTAL – Compression and cylinder leakage tests 100 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 16 DBE/PAT 2022 NSC TASK 2: GAS ANALYSING TEST – QUESTIONS WORKSHEET 2.1 NAME: QUESTIONS MARK TOTAL 2.1.1 What is the purpose of using a gas analyser on an internal combustion engine? 2 2.1.2 State TWO faults that would prompt you to analyse the exhaust gases of an internal combustion engine. 2 2.1.3 Name SIX gases that can be analysed by the exhaust gas analyser. 6 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 17 DBE/PAT 2022 NSC 2.1.4 State THREE safety precautions that must be adhered to when conducting an exhaust gas analysis. 3 2.1.5 State FOUR causes of improper and incomplete combustion. 4 2.1.6 What is the ideal air/fuel ratio for a spark ignition engine? 1 TOTAL – Gas analysing test – Questions 18 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 18 DBE/PAT 2022 NSC TASK 2: GAS ANALYSING TEST – PROCEDURE WORKSHEET 2.2 NAME: EXHAUST GAS ANALYSIS 2.2 Conduct an exhaust gas analysis on an internal combustion engine, following the correct sequence. PROCEDURE MARK TOTAL 2.2.1 Obtain the manufacturer' oxygen (O2), carbon monoxide (CO) and carbon dioxide (CO2) exhaust gas specifications for the engine to be 3 tested. REASON: 2.2.2 Ensure proper ventilation when 2 conducting test. REASON: 2.2.3 Bring engine to 2 operating temperature. 2.2.4 Ensure filters on analyser are clean. 1 REASON: 2.2.5 Check for any exhaust 3 leaks. REASON: 2.2.6 Check for any vacuum 2 leaks. REASON: 2.2.7 Switch on the gas analyser (connect cables 2 to battery terminals or use switch). Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 19 DBE/PAT 2022 NSC REASON: 2.2.8 Calibrate the analyser. 2 2.2.9 Ensure that the inlet hose is not restricted. 1 2.2.10 Insert probe into exhaust tailpipe. 1 2.2.11 Take the readings of the exhaust gases. (Choose any TWO of the following three gases, i.e. CO, O2 and CO2) (a) CO% results obtained 1 CONCLUSION: Compare CO% reading with specifications. 4 (b) O2% results obtained 1 CONCLUSION: Compare O2 reading with specifications 4 (c) CO2% results obtained 1 CONCLUSION: Compare CO2 reading with specifications 4 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 20 DBE/PAT 2022 NSC 2.2.12 Disconnect the analyser. 1 2.2.13 Remove the probe from the exhaust pipe. 1 2.2.14 Remove condensate from pipes. 1 TOTAL – Gas analysing – Procedure 32 TOTAL – Gas analysing – questions 18 TOTAL – Gas analysing – procedure 32 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 21 DBE/PAT 2022 NSC TASK 3: WHEEL BALANCING – QUESTIONS WORKSHEET 3.1 NAME: QUESTIONS MARK TOTAL 3.1.1 State THREE advantages of having the motor vehicle's wheels 3 balanced. 3.1.2 Why is it necessary for the wheel-balancing machine to be correctly 1 calibrated? 3.1.3 State THREE functions of the wheel-weight hammer. 3 3.1.4 Define static balance of a wheel and tyre assembly. 2 3.1.5 Define dynamic balance of a wheel and tyre assembly. 2 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 22 DBE/PAT 2022 NSC A B C 3.1.6 FIGURE 3.1.6 indicates different tyre wear conditions. State 3 the cause of EACH condition A–C. FIGURE 3.1.6 A– B– C– 3.1.7 State THREE safety measures that should be observed when 3 performing wheel balancing. TOTAL – Wheel balancing – Questions 17 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 23 DBE/PAT 2022 NSC TASK 3: WHEEL BALANCING – PROCEDURE WORKSHEET 3.2 NAME: WHEEL BALANCING 3.2 Balance a wheel and tyre assembly using the correct procedure. PROCEDURE MARK TOTAL 3.2.1 Choose the correct rim adapter for the rim size. 1 3.2.2 Fit wheel to the wheel balancer correctly. 1 3.2.3 Check the tyre for uneven wear. 1 3.2.4 Check the tyre for bruises, cracks, and damaged side walls. 1 3.2.5 Check tyre wear at the tyre wear indicators (TWI). 1 3.2.6 Remove foreign matter from the rim and tyre. 1 3.2.7 Check the wheel rim for damaged beads. 1 3.2.8 Obtain the wheel rim diameter from the tyre. 1 3.2.9 Enter wheel rim diameter into the wheel balancer. 1 3.2.10 Check tyre pressure. 1 3.2.11 Use the calliper to obtain the rim width. 1 3.2.12 Enter wheel rim width into the wheel balancer. 1 3.2.13 Use the off-set arm to measure the distance to the wheel 1 3.2.14 Enter measurement into the wheel balancer. 1 3.2.15 Close safety cover. 1 3.2.16 Switch on the balancer and allow wheel to spin 1 REASON: 3.2.17 Obtain the imbalance reading on outer and inner 2 part of the rim. 3.2.18 Remove wheel weights. 1 3.2.19 Switch on wheel balancer to measure balancing on outer part of the 1 rim. 3.2.20 Close safety cover. 1 3.2.21 Switch on the balancer and allow wheel to spin. 1 3.2.22 Obtain the imbalance readings and its location on outer part of the 1 rim. 3.2.23 Choose the correct weights. 1 3.2.24 Fit the weights correctly on the rim. 1 3.2.25 Switch wheel balancer on to measure balancing on inner part of the 1 rim. 3.2.26 Close safety cover. 1 3.2.27 Switch on the balancer and allow wheel to spin 1 3.2.28 Obtain the imbalance readings and its location on inner part of the rim 1 3.2.29 Choose correct weights. 1 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 24 DBE/PAT 2022 NSC 3.2.30 Fit the weights correctly on the rim. 1 3.2.31 Re-check balancing. 1 3.2.32 Remove wheel when it is balanced. 1 TOTAL – Wheel balancing – Procedure 33 TOTAL – Wheel balancing – Question 17 TOTAL – Wheel balancing – Procedure 33 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 25 DBE/PAT 2022 NSC TASK 4: CHARGING SYSTEM – PROCEDURE WORKSHEET 4 NAME: CHARGING SYSTEM (ALTERNATOR) QUESTION MARK TOTAL 4.1 Identify any SEVEN parts (A–I) of the alternator in FIGURE 4.1. 7 C G A H E I D F B FIGURE 4.1 A. B. C. D. E. F. G. H. I. 4.2 Test the charging system on a vehicle. PROCEDURE MARK TOTAL 4.2.1 Obtain the manufacturer's specifications 2 for the vehicle charging system. 4.2.2 Check for loose electrical connections. 1 4.2.3 Check the fan belt. 1 4.2.4 Use multimeter to measure the battery voltage of the vehicle's idling. 2 4.2.5 Measure battery voltage with load. 2 TOTAL – Charging System – Procedure 15 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 26 DBE/PAT 2022 NSC 4.3 Test the following components of a dismantled alternator. PROCEDURE MARK TOTAL Check the six diodes on the rectifier. 4.3.1 Select continuity (buzzer) on the multimeter. 1 4.3.2 Connect the multimeter to both sides of the diode. 6 4.3.3 Report condition of diodes. 6 Check stator for continuity. 4.3.4 Connect the multimeter to the common connections and the other 3 end to each of the three winding ends respectively. 4.3.5 Report on the continuity of 3 the stator windings. Check stator for earth leakage. 4.3.6 Connect the multimeter to the stator framework and the other end 3 to each of the three winding ends respectively. 4.3.7 Report on the earth leakage 3 of the stator windings. Check rotor for continuity. 4.3.8 Connect multimeter to both slip rings. 1 4.3.9 Report on the continuity of 1 rotor windings. 4.3.10 Check if slip rings are connected properly to rotor windings. 2 4.3.11 Check slip rings for wear. 1 Check rotor for earth leakage. 4.3.12 Connect multimeter to rotor winding and rotor framework. 1 4.3.13 Report on the earth leakage 1 of rotor windings. 4.3.14 End bracket/Cover for wear. 1 4.3.15 Check front and rear bearings. 2 TOTAL – Alternator – Procedure 35 TOTAL – Charging System – Procedure 15 TOTAL – Alternator – Procedure 35 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 27 DBE/PAT 2022 NSC TASK 5: FUEL PRESSURE TEST– QUESTIONS WORKSHEET 5.1 NAME: ________________________________________________ QUESTIONS MARK TOTAL 5.1.1 State the function of the fuel pressure tester. 2 5.1.2 Name TWO methods by which fuel pumps are driven on an internal 2 combustion engine. 5.1.3 State the function of a fuel filter. 2 5.1.4 State TWO functions of a check valve in the fuel system. 2 5.1.5 State TWO possible faults and their corrective measures for low fuel pressure. 4 FAULT CORRECTIVE MEASURE (Any 2 x 2) TOTAL – Fuel pressure test – Questions 12 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 28 DBE/PAT 2022 NSC TASK 5: FUEL SYSTEM TEST – PROCEDURE WORKSHEET 5.2 NAME: ________________________________________________ 5.2 Conduct the fuel system pressure test in the correct sequence. PROCEDURE MARK TOTAL 5.2.1 Obtain the fuel pressure specifications: 3 5.2.2 Work in a well-ventilated area. 1 5.2.3 Ensure there is fire extinguisher nearby. 1 5.2.4 Obtain the correct adaptor in accordance with the hose size. 1 5.2.5 Ensure that the tester can read the pressure of the fuel system. 1 5.2.6 Ensure that the rubber hose is not perished on the tester. 1 5.2.7 Ensure that the tester's pressure relieve valve is working properly. 1 5.2.8 Switch ignition on and off after the full pressure is reached. 2 5.2.9 Fit fuel pressure 2 tester to fuel line. 5.2.10 Switch ignition on and off after the full pressure is reached. 2 5.2.11 Check fuel pressure on 3 gauge. 5.2.12 Release pressure and connect to fuel hose on engine side as well. 2 5.2.13 Switch ignition on and off after the 2 full pressure is reached. 5.2.14 Check fuel pressure 2 on gauge. 5.2.15 Check regulator vacuum 2 hose for wetness. 1. 2. 5.2.16 Check for leaking injectors. 4 3. 4. TOTAL – Fuel system test – Procedure 30 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 29 DBE/PAT 2022 NSC 5.3 Check the fuel delivery rate. PROCEDURE MARK TOTAL 5.3.1 Obtain the delivery rate (fuel flow rate) specifications. 1 5.3.2 Release fuel pressure from fuel system. 2 5.3.3 Disconnect fuel hose. 1 5.3.4 Insert fuel hose into measuring beaker. 1 5.3.5 Switch ignition on. 1 5.3.6 Measure the fuel delivery volume after ONE minute. 2 TOTAL – Fuel delivery rate – Procedure 8 TOTAL – Fuel pressure test – Questions 12 TOTAL – Fuel system test – Procedure 30 TOTAL – Fuel delivery rate – Procedure 8 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 30 DBE/PAT 2022 NSC TASK 6: ENGINE COMPONENTS MEASUREMENT AND CALCULATIONS – QUESTIONS WORKSHEET 6.1 NAME: ________________________________________________ QUESTIONS MARK TOTAL 6.1.1. Explain what is meant by swept volume. 2 6.1.2. Define clearance volume. 2 6.1.3. What do you understand by the term compression ratio? 2 6.1.4. Describe THREE methods of raising the compression ratio in an 3 engine. 6.1.5. Describe THREE methods of lowering the compression ratio in 3 an engine. Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 31 DBE/PAT 2022 NSC 6.1.6. Use the following data to calculate the compression ratio: Stroke length = 80 mm 6 Bore diameter = 70 mm Clearance volume = 35 cm3 TOTAL - Engine components measurement and calculations – Questions 18 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 32 DBE/PAT 2022 NSC TASK 6: ENGINE COMPONENTS MEASUREMENT – PROCEDURE WORKSHEET 6.2 NAME: ________________________________________________ ENGINE COMPONENTS MEASUREMENT 6.2 Measure the cylinder bore and crankshaft journal of an internal combustion engine. Answer the questions that follow. PROCEDURE FIGURE 6.2: ENGINE BLOCK, CRANKSHAFT AND CONROD ASSEMBLY 6.2.1 Obtain specifications for the following: COMPONENT SPECIFICATION MARK TOTAL Big-end journal 1 Main journal 1 Cylinder-bore diameter 1 Stroke length 1 Big-end bearing clearance 1 Mains-bearing clearance 1 TOTAL – Engine specifications 6 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 33 DBE/PAT 2022 NSC 6.2.2 Measure the main journal. A1 A2 B1 B1 B2 B2 A1 A2 FIGURE 6.3: MAIN JOURNAL DIMENSION MEASUREMENT MARK TOTAL A1 2 A2 2 B1 2 B2 2 6.2.3 Calculate the ovality. A1 – B1 = 1 A2 – B2 = 1 6.2.4 Calculate the taper. A1 – A2 = 1 B1 – B2 = 1 TOTAL – Engine main journal measurement and calculations 12 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 34 DBE/PAT 2022 NSC 6.2.5 Measure the cylinder bore. B2 A2 A2 B2 B1 A1 A1 B1 FIGURE 6.4: CYLINDER BORE DIMENSION MEASUREMENT MARK TOTAL A1 2 A2 2 B1 2 B2 2 Stroke length 2 6.2.6 3 Calculate the ovality: A1 – B1 = 1 A2 – B2 = 1 6.2.7 3 Calculate the taper: A1 – A2 = 1 B1 – B2 = 1 TOTAL - Engine cylinder measurement and calculations 14 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 35 DBE/PAT 2022 NSC TOTAL – Engine components measurement and calculations – Questions 18 TOTAL – Engine specifications 6 TOTAL – Engine main journal measurement and calculations 12 TOTAL – Engine cylinder measurement and calculations 14 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 36 DBE/PAT 2022 NSC TASK 7: COMPUTERISED DIAGNOSTIC SCANNER – QUESTIONS WORKSHEET 7.1 NAME: ________________________________________________ QUESTIONS MARK TOTAL 7.1.1 What do the following abbreviations stand for? (a) OBD 1 (b) ECU 1 (c) TCU 1 (d) MAF 1 (e) TPS 1 7.1.2 Interpret the following fault code P0171: (a) P 1 (b) 0 1 (c) 1 1 (d) 71 1 7.1.3 State the FOUR operational processes of an ECU. 4 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 37 DBE/PAT 2022 NSC 7.1.4 State TWO manufacturer's specifications required to set up an 2 OBD scanner. 7.1.5 State THREE basic functions of an OBD scanner. 3 7.1.6 Name FOUR systems that the OBD can detect and that are managed 4 by the ECU. TOTAL – Computerised diagnostic scanner – Questions 22 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 38 DBE/PAT 2022 NSC TASK 7: COMPUTERISED DIAGNOSTIC SCANNER WORKSHEET 7.2 NAME: ________________________________________________ COMPUTERISED DIAGNOSTIC SCANNER 7.2 Conduct a computerised diagnostic test on a vehicle using the OBD-II scanner. PROCEDURE MARK TOTAL 7.2.1 Check for obvious problems:   Fuel leaks and fuel level  Vacuum hoses that are disconnected or split  Corroded connectors  Unusual noises, smoke, or smell 6  Check the air filter  Check the oil level and condition  Check the coolant level and condition  Check the battery voltage (Any 6 x 1) 7.2.2 Obtain the VIN of the vehicle. 1 7.2.3 Obtain make and model of the vehicle. 1 7.2.4 Locate the car's OBD-II port. 1 7.2.5 Gain access to the car's OBD-II port. 1 7.2.6 Plug the diagnostic tool into the OBD-II port. 2 7.2.7 Access the diagnostic scanner. 2 7.2.8 Enter the vehicle's details into the scanner. 2 7.2.9 Turn on the vehicle's ignition. 2 7.2.10 Perform a diagnostic scan. 2 7.2.11 Record any diagnostic trouble codes. 2 7.2.12 Clear the trouble codes and restart the diagnostic scan. 2 7.2.13 Interpret the trouble codes and make a diagnosis 4 TOTAL – Computerised Diagnostic Scanner – Procedure 28 TOTAL – Computerised diagnostic scanner – Questions 22 TOTAL – Computerised diagnostic scanner – Procedure 28 GRAND TOTAL 50 Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 39 DBE/PAT 2022 NSC 5. SUMMARY MARK SHEET – TOTALS MECHANICAL TECHNOLOGY AUTOMOTIVE MARK SHEET – TOTALS GRADE 12 DATE LEARNERS MARKS FACETS 1 2 3 4 5 6 7 8 9 10 PHASE 1 50 TASK …… PHASE 2 50 TASK …… PHASE 3 50 TASK …… PHASE 4 - 100 TASK 1 ….. TOTAL: 250 TOTAL PAT 100 MARK: NAME AND SIGNATURE OF TEACHER NAME AND SIGNATURE OF TECHNICAL DEPARTMENT HEAD NAME AND SIGNATURE OF PRINCIPAL NAME AND SIGNATURE OF SUBJECT MODERATOR Copyright reserved Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 40 DBE/PAT 2022 NSC 6. ANNEXURE A SPECIFICATIONS SHEET ENGINE: FUEL: Type Fuel system Bore and stroke Aspiration Idling speed Consumption Power max. CO emissions Torque max. CO2 emissions Compression ratio O2 emissions Oil pressure Fuel type Firing order Fuel system Radiator cap pressure Aspiration Thermostat opening Consumption pressure CO emissions TRANSMISSION: CO2 emissions Clutch type and diagram O2 emissions Gearbox Rear axle type PISTONS AND RINGS: Piston clearance in Final drive type and ratio bore Speed on top gear per Oversizes 1 000 r/min No. of rings CAPACITIES: Groove clearance Sump without oil filter Ring gap in bore Gearbox Final drive Cooling system Fuel tank Copyright reserved

Downloaded from hlayiso.com Mechanical Technology: Automotive 41 DBE/PAT 2022 NSC VALVES: CRANKSHAFT: Working clearance 5 main bearings Inlet Undersizes Exhaust Clearance Timing Big end In opens Undersizes In closes Clearance Timing Small end bushes Exhaust opens Exhaust closes TORQUE SETTINGS: Spring free length Flywheel Spring rate Cylinder head Seat angle Big ends Valve lift Main bearings Cam height OHC bearing caps IGNITION AND ELECTRICAL: Distributor type Stroboscopic setting Position of timing marks Spark plugs Spark plugs gaps Battery Alternator Charging rate Regulator type Copyright Please turn over

Downloaded from hlayiso.com Mechanical Technology: Automotive 42 DBE/PAT 2022 NSC 7. CONCLUSION On completion of the practical assessment task learners should be able to demonstrate their understanding of the industry, enhance their knowledge, skills, values and reasoning abilities as well as establish connections to life outside the classroom and address real-world challenges. The PAT furthermore develops the learner's life skills and provides opportunities for learners to engage in their own learning. Copyright reserved