Trainers Assessment Resource

AUR50216

Version: 2.0 Acumen Education Pty Ltd © Page 1 of 76

Student Name:

Student ID:

Assessment Summary

Unit Details 11 - AURLTD007 – Analyse and evaluate faults in light vehiclesteering and suspension systems

Assessment Type

This is a summative assessment, which requires each student to have adequate practice prior to undertaking this assessment This assessment Must also be undertaken in a simulated automotive workshop

Assessment Methods

Assessment 2 Demonstration

Neeraj SAINI

SAE7599


Assessment Tool| AURLTD007

For Assessor Only -PRACTICAL ASSESSMENT COVER SHEET This form is to be completed by the assessor and used as a final record of student competency.

All student submissions including any associated checklists (outlined below) are to be attached to this cover sheet before placing on the students file. Student results are not to be entered onto the Student Database unless all relevant paperwork is completed and attached to this form.

Student Name: Student ID No:

Email: Contact number:

Unit Code & Title

AURLTD007 – Analyse and evaluate faults in light vehicle steering and suspension systems

First Submission Subsequent Submission

Please attach the following documentation to this form Result

S = Satisfactory NS = Not Satisfactory

Assessment 2 Demonstration – Analysis reports S | NS

Practical Result for this unit Satisfactory

The Evidence provided is:

Valid Sufficient Authentic Current

Student Declaration: I acknowledge that I understand the requirements to complete the assessment tasks. The assessment process including the provisions for re-submitting and academic appeals were explained to me and I understand these processes. I understand the consequences of plagiarism and confirm that this is my own work and I have acknowledged or referenced all sources of information I have used for the purpose of this assessment.

Student’s Signature: Date: _______/_______/_______ Trainer feedback:

Assessor: I declare that I have conducted a fair, valid, reliable and flexible assessment with this student, and I have provided appropriate feedback.

Signature:

Date: _______/_______/_______

Administrative use only

Entered onto Student Management Database ________________

Date ________________

Initials

Not Satisfactory

Neeraj SAINI SAE7599

[email protected] 424636938

03 06 2021

You have clearly identified the purpose of the analysis and performed the analytical procedures in logical order. Throughout theprocess you have made correct choices of tools to use and demonstrated the skills following OHS procedures. Good use ofworkshop manuals for technical specifications and developing evaluation. Completed the given task by demonstrating punctualattitude and completed the documentation.

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Assessment 2 – Practical demonstration

Instructions for Students: • This is the second of the two assessment tasks you must complete satisfactorily to be

deemed competent in this unit. • In this task, you must demonstrate your ability to analyse and evaluate a fault in the

steering and suspension system of three different vehicles (simulated) This assessment has 3 sub-tasks. You must complete all the sub-tasks successfully for a satisfactory result. Please be guided by task specific instructions on the following pages. • Your assessor will observe you performing this task and record and assess your performance

in the Skill Observation Checklist. • Read the Assessment description carefully. • Assessment must be completed in the simulated automotive workshop. • You will have 6 hours to complete this assessment. • You must wear appropriate PPE before entering the workshop • Clearly label your work with name, unit code and unit title to all the documents and sheets

that are attached to your submission. • Review the Observation Checklist so that you are familiar with the behaviours that you are

expected to perform during the observation. • Review other resources, tools, job aids that provide guidance related to the task you are

going to perform. • Read the Plagiarism policy and procedure carefully to understand the consequences that

you could face if your work is plagiarized. • Seek clarification regarding the assessment required to be done, if you do not understand

the task. • Ask for reasonable time from Assessor for preparation of Assessment. • Seek information on additional reading material and reference for completion of the

assessments. • Students with special needs can seek assistance from assessors depending upon the

nature of the need. • Submit this document along with your assessment work. Decision-making rules • To achieve a satisfactory result, you must demonstrate the ability to ‘Analyse and evaluate

faults in light vehicle steering and suspension systems in an automotive workplace’ independently that meet all the criteria mentioned in the instructions for assessment.

• No marks or grades are allocated for this assessment task. The outcome of the task will be Satisfactory or Not Satisfactory.

• You must answer any questions asked by your assessor and demonstrate all skills to the required level.



• You must speak to your Assessor if you have any difficulty in completing this task and require reasonable adjustments.

WARNING!

The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or dangerous way.



Resources required for assessment: The assessor must ensure that the resources mentioned in the assessment conditions section of this document are made available to students, for assessment:

Resources • Access to the internet • Markers and pens • Access to a computer/Internet for

online technical help • Material safety data sheets • WHS procedures:

o Occupational Health and Safety (OHS) guidelines

o Safety instructions from the business/employer

o Vehicle or system safety precautions given by the vehicle manufacturer.

• Manufacturer light vehiclesteering and suspensionsystem specifications

• Simulated workplace • Job cards • Three different light vehicles withsteering

and suspension system faults (simulated)

Tools / equipment required Personal Protective Equipment Hand tools • Spanners • Sockets & Ratchets • Extension Bars • Pliers • Screw Drivers • Sharp Knife / Blade • Measuring tape • Spring compressor tool Pneumatic Tools • Impact Wrench (Rattle Gun) • Air Ratchet • Blow Gun Jacks & lifts • Two Post Hoist • Hydraulic Jack • Wheel chokes • Safety stands Special Diagnostic Tools • Stethoscope • Pressure Gauge • Scan tool • Belt tension gauge

• Hearing protection • Hand protection • Skin protection • Protective clothing • Protective footwear • Eye protection • Safety helmet



Observation Task Scenario Task 1 For this task, you will be observed analysing and evaluating a fault in the steering system of a light vehicle: The customer drives a vehicle into the workshop with concern that Vehicle makes loud groaning noise while turning. Task 2 For this task, you will be observed analysing and evaluating a fault in the suspension system of a light vehicle: The customer complains about the bumpy ride while driving and notices vibration and wandering of the steering wheel when driving at40km/hour or more. Hint: The workshop manual’s flow chart reflects “suspension system” as the top priority cause. Task 3 For this task, you will be observed analysing and evaluating a fault in the steering system of a light vehicle: Customer complaint, steering wheel is becoming hard and making grinding noise while making turns. The steering wheel is also operating very rough has power steering fluid leaks.



Student Instructions • Your trainer will direct you to a vehicle (Simulated) to work on. • You should access and interpret manufacturer specifications and other technical

information relating to light vehicle steering and suspension system from the workplace documents provided.

• Make sure you identify any hazards while performing the task. Manage the obvious risks and use appropriate control measures.

• You must follow WHS requirements at all times, including proper use of PPE. • Choose, prepare and collect all the necessary tools and equipment required for analysis

and follow steps to ensure they are operational before use. • Identify and confirm the purpose of the analysis. • Collect vehicle information and specification. Identify and confirm faults and

discrepancies. • Develop evaluative criteria for analysis. • Follow the repair manual and prepare for the diagnostic procedure. • Identify the components for analysing the cause of faults in steering and suspension

systems of a light vehicle (simulated) • Identify diagnostic method from available options and undertake all the steps involved in

performing the failure analysis which may involve checking the following: o present trouble shoot method according to manufacturer specification to carry out

failure analysis o present testing procedure used for relevant components following all safety and

environmental requirements o while performing testing you should also complete measurements, calculate analytical

requirements wherever required, calibrate testing equipment and present analytical results

o confirm your findings using reliable process, for instance replacing the faulty component and check if the symptoms still present

o compare the readings with repair manual o analyse the symptoms and arrive at conclusion o identify the nature and cause of fault as a component failure or system failure o provide various possible suggestions to resolve the issue and choose the best possible

option after taking into account different variants such as time, cost and available resources

o be sure to pay attention to any regulatory requirement and Australian design rules that may need to be addressed while making recommendations

• Validate the work to meet workplace expectations by undertaking a final inspection and making sure there are no damages to the components or systems.

• Outline recommendations based on the analysis. • Clean up the work area and maintain equipment following workshop procedures including

disposal of waste and non-recyclable material, and collection of recyclable material. • Check and store all electrical and mechanical tools and equipment upon completion of

work in accordance with procedures to handle broken tools. You should accurately fill out the document when reporting failure analysis. The report should be written legibly (be easy to read).



Fill out the below repair report for the mentioned task while undertaking practical assessment – Task 1

Acumen simulated workshop

Repair Order 1

Customer Details Vehicle details (Must fill in the vehicle details) If simulated vehicle used please tick

Customer name & address:

ABC Martin Richmond Victoria

Make: VIN No: Trans Type:

Contact Details:

03 9044 6402 Model: Odometer

Reading:

Email address Colour: Engine No:

Reg No: Engine Type:

Service History

Date RO Number Kms Type of service Job Description

Customer Concern The customer drives a vehicle into the workshop with concern that vehicle makes loud groaning noise while turning.

Declaration by The Customer I understand, that the repairs shall be carried out within flat rate hour time. Should any further repairs become necessary, I shall be contacted for my permission, time and possible cost. I authorise carrying the work prescribed above and agree to pay labour/parts charges applicable. I shall be notified of any replaced parts prior to my vehicle being delivered. Any claims for faulty workmanship is to be raised within seven (7) working days after the vehicle is returned to me. I agree such claim is limited solely to the rectification free of cost of the faulty work. No claim for loss consequential or otherwise being admissible.

Signature of Owner Date (Fill in the date)

Martin

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Verify the concern (Purpose of analysis)

Resources used (Tools, Specifications)

Frequency of the problem All the time. Noise increasing when turning the steering wheelHistory of the vehicle As per customer, no previous issuesService maintenance history Not availableCustomer concern Abnormal noise observed from the engineSymptoms noticed Noise at engine idle speed

SpannersSockets & RatchetsStethoscopePressure GaugeRepair manualBelt tension gaugeExtension BarsPliersScrew Drivers



Test criteria

Fault diagnosis

Test Test results (Actual readings)

Manufacturer specifications (Qualitative or quantitative)

Specified PID values

pump belt tension inspection,Fluid leakage inspection,Pump noise inspection andFluid pressure testingPower steering system inspection includingfluid level, condition of fluid,Steering column damaged or wornLoose suspension bushings, bolts, or ball jointsSteering system inspection includingSteering column shaft/coupling joints damaged or worntie rod ends for looseness, damages, or weargear insulators mounting bolts inspection for looseness or damages

Power steering fluidlevel and conditionPower steering pumpbelt tensioninspectionPower steering fluidleakage inspectionFluid pressure testingPump noiseinspection usingstethoscopeSteering columnshaft/coupling jointsinspection

Low level, blackish coloured aerated fluidNo cracks foundBelt tension found 410NmNot found any leaks near the hoses, lines, pump,and steering rack assembly.Found low pressure 70psFound growling noise in power steering pump atengine idle conditionSteering column shaft/coupling joints inspection

Up to Maximum level, Not contaminated or burnt.Used belt tension- 390 540 NNew belt 740 880 NNo cracksNo leakages at any of the steering systemcomponentsAt engine idle condition 1500kPa (15kgf/cm², 213 psi)No noise at idle and while turning steering wheelNo damage, No loose



Tie rod endsinspectionSuspensionbushings, ball jointsand bolts inspection

Found outer tie rod end worn and excessive playNo looseness in boltsNo damages to any suspension bushingNo excessive play in steering rack inner bolljoint

No play in tie rod endNo damages, Not worn or loose



Reason for component and / or system failure

Repair recommendation (Recommendation should also include parts to be used):

Conclusion (Analysis of results): Power steering issuesNoticed contaminated fluid,Identified groaning noise in power steering pump at engine idle conditionSteering system issuesIdentified steering column coupling joint loose and crackedFound outer tie rod end worn out and excessive playConclusionPower steering internally damaged or worn out components.

Power steering pump damaged internally due to contaminated fluid.Noises observed due to steering column coupling joint being loose and crackedKnocking noise on rough surfaces noticed because of outer tie rod end worn out

Replace the new power steering pump and replace with new power steering fluid as per manufacturer procedureand specifications.Replace the steering column coupling jointReplace the out tie rod and perform wheel alignment



Skill Observation Checklist and Assessment Outcome: Assessment 2, Task 1

Student name

Unit and Task being assessed


Course name and title AUR50216 - Diploma of Automotive Technology

Date of observation

Vehicle (Simulated) – 1: Analyse fault in light vehicle steering system

Did the Student: Satisfactory Comments

Confirm the work requirement Yes No

Research specifications related to light vehicle steering system from a range of sources

Yes No

Identify and confirm the system faults

Yes No

Identify the hazards related to the task

Yes No

Manage risks using appropriate control measures

Yes No

Follow all safe operating procedures, including those associated with: • Vehicle & machinery

movement• Toxic substances• Electrical safety• Working in proximity to others

Yes No

Select and wear appropriate PPE throughout inspection

Yes No

Develop evaluative criteria to analyse the fault (TEST Criteria)

Yes No

Identify the evaluative methodology to be used based on the fault

Yes No

Prepare the testing equipment and tools required for the task

Yes No

Start the diagnostic process Yes No

Neeraj SAINI

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Prepare the vehicle for diagnosis Yes No

Carry out testing in accordance with manufacturer specifications, safety and environmental requirements

Yes No

Carryout system failure analysis Yes No

Carryout component failure analysis Yes No

Verify analytical and other diagnostic findings using reliable alternative or optional processes

Yes No

Assess the findings and results against evaluation criteria Yes No

Identify the actual fault and arrive at conclusion Yes No

Performs further research of technical support information Yes No

Select the rectification method from analysis of the options, operating conditions, regulatory requirements, Australian Design Rules, and financial implications

Yes No

Prepare the analysis report by specifying analysis and evaluation process accurately and legibly

Yes No

Detail and justify the rectification method or variation to the rectification method chosen

Yes No

Undertake a final inspection to ensure work is as per expectations

Yes No

Read the job card and understood the purpose of theanalysis and the problem of the vehicle.Performed visual inspection to identify fault.Followed manufacturer specifications and repair manualsto inspect trouble symptoms.Developed evaluation criteria to analyse the faults whilechecking fluid level, leaks, fluid circulation, pressure testand component analysisInspected the belt condition and tension as per themanufacturer specifications. Checked the fluid for its colorand odour. Inspected the fluid for any metal particles in it.Checked the temperature of the power steering fluid.Monitored the power steering pressure with scan tool.Recorded the fluid pressure with steering wheel instraight-ahead position and with idle engine speed.Compared the fluid pressure readings with manufacturerspecification and adjusted as per the standardspecifications. Checked the noise on the pump. Visuallyinspected steering column for excessive damage.Performed radial axial movements to inspect tie rod end.Visually inspected the suspension components for anydamage.Verified the diagnostic findings with appropriatealternative or optional processes. Checked the steeringfor hardness while turning. Inspected the engine noisewhile turning the steering.Flushed the power steering pump with new fluid.Replaced steering column coupling joint. Replacedsteering outer tie rod as per the recommendations andrequirements of ADRs.✔

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Clean up the work area and dispose all the non-recyclable material in line with environmental requirements

Yes No

Collect and store all the recyclable material effectively

Yes No

Correctly complete workplace documentation following standard operating procedure

Yes No

Result: Satisfactory Not Satisfactory Not Assessed

Assessor Declaration: I declare that I have conducted a fair, valid, reliable and flexible assessment with this student, and I have provided appropriate feedback.

Assessor Name:

Assessor Signature: Date: _______/_______/_______ Student Declaration: I have read and agree with this assessment record.

Student Signature: Date: _______/_______/_______

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Repair Order 2





Contact Details:


Reading:



Service History


Customer Concern The customer complains about the bumpy ride while driving and notices vibration and wandering of the steering wheel when driving at 40km/hour or more.

Hint: The workshop manual’s flow chart reflects “suspension system” as the top priority cause.


Signature of Owner Date (Fill in the date)

Martin

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Purpose of analysis

Resources used (Tools, Specifications)

Customer concern Abnormal ride quality and vibrationsSymptoms noticed Steering wandering and vibrationsFrequency of the problem When driving at 40 kmphHistory of the vehicle As per customer, no previous issuesService maintenance history Done regular service

SpannersSockets & RatchetsExtension BarsPliersWheel chokesTwo post hoistMeasuring tapeScrew Drivers



Test Criteria

Fault diagnosis

Test Test results

(Actual readings)



Front and rear rideheight measurementsNoise testBOUNCE TESTSteering ball joint testMacpherson strut test.Lower arm bushes andball jointsShock top mountingand shock absorbercondition and operationchecksInspection of coil springof strut assemblycondition and cushioncondition

Found sagging at one sideSqueaking noise observedBounce test failedFound excessive ball joint movementFound oil leaksNoticed insufficient resistance from the shock absorberwhen it is pushed up or downFound lower arm bushes cracksFound broken top mountCushion found tear

No sagging.NO noise while bouncingThe vehicle bounce should stop after 1 1.5bounces.No excessive movementSufficient resistance and no oil leakevidenceNo cracks and no damages.No cracks and no damagesNo tear and no damage

Suspension system inspectionVehicle BOUNCE TESTNoise inspectionFront and rear ride height measurementsSteering ball joint inspection for playLower arm bushes and ball jointsMcpherson strut test.Shock absorber condition and operation checksCoil spring of strut assembly condition and cushion condition broken or tearInspection strut buffer of the shock



Inspection of strutbuffer of the shock

Found cracked No cracks or damages



Analysis of results: Reason for component and /or system failure Repair recommendation

Found one side of the vehicle is sagging due to incorrect ride heightBounce test failed indication shock absorber failureObserved the squeaking noise which is indicating problem with the suspension.Evidence of oil leakTOP MOUNTING found cracked for Macpherson strut.Coil spring cushion found torn.The strut buffer/stopper found cracked on inspection.Found excessive movement in steering ball joint.Found insufficient resistance in Macpherson strut when pushed up or down

Replace following components:Macpherson strut assembly,strut buffer,coil spring seat(cushion), and strut top mountingSteering inner ball joint

Customer noticedpoor ride quality due to incorrect ride height and vehicle sagging on one side.steering wandering due to steering ball joint excessive play andvibrations because of suspension strut internal failures like oil leaks, mounting damages and coil springdamaged cushion and buffer cracks




Student name




Date of observation

Vehicle (Simulated) – 2: Analyse fault in light vehicle suspension system



Research specifications related to light vehicle suspension system from a range of sources

Yes No


Yes No

Identify and remove the hazards related to the task

Yes No


Yes No



Yes No


Yes No


Yes No


Yes No


Yes No

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Prepare the vehicle for diagnosis

Yes No


Yes No

Carryout system failure analysis

Yes No

Carryout component failure analysis

Yes No


Yes No

Assess the findings and results against evaluation criteria

Yes No

Identify the actual fault and arrive at conclusion

Yes No

Performs further research of technical support information

Yes No


Yes No


Yes No


Yes No


Yes No


Yes No

Read the job card and understood the purpose of theanalysis and the problem of the vehicle.Performed visual inspection to identify fault.Followed manufacturer specifications and repair manualsto inspect trouble symptoms.Developed evaluation criteria to analyse the faults whilechecking fluid level, leaks, fluid circulation, pressure testand component analysisSuspension components were inspected for physicaldamage. Carried out bounce test, Macpherson strut testand steering ball joints test. Measured ride height. Topmounting and shock absorber were checked for conditionand operation. Inspected the coil spring of strut assembly.Checked inner buffer of the shock for any damage.Confirmed that the ride height measurements does notmatched with specifications. Coil spring cushion wasfound cracked. Confirmed that the lower arm bushes werefound cracked. Identified leaking strut. Confirmed that theMacpherson strut top mounting was cracked.

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Yes No


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Assessor Name:



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Amitkumar Patel

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Repair Order 3





Contact Details:


Reading:



Service History


Customer Concern Customer complaint, steering wheel is becoming hard and making grinding noise while making turns. The steering wheel is also operating very rough and has power steering fluid leaks.


Signature of Owner Date (Fill in the date) Martin

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Verify the concern (Purpose of analysis) Resources used (Tools, Specifications) Test Criteria

Customer concern Hard steering and grinding noise while turning. Also noticed steering wheel operating veryrough and power steering fluid leaks.Symptoms At all speeds and all road conditionsFrequency of the problem All the time. Confirmed that the Steering wheel is not rotating freely at vehiclestationary condition and when engine is in idle condition.Previous history of the vehicle No previous issues.Periodic service maintenance history Not availableSystems affected are:1. Drivability issues.2. Tyres3. Wheel alignment

Repair manualExtension BarsPliersScrew DriversAir RatchetBlow GunPressure gaugeImpact Wrench (Rattle Gun)SpannersSockets & Ratchets

Visual Inspection of steering systemSteering column testPower steering Hoses checksBall joint testPressure testSuspension component test



Fault diagnosis

Test Test results (Actual readings)



Visual Inspection ofsteering systemSteering column testBall joint testSuspension componenttestPower steering fluid testPressure testPower steering HosesSteering rack assemblymounting test

No physical damages foundFound moisture in power steering fluidNo looseness in joints and not found any physicaldamagesNo excessive movement noticedNo damages and no missing bushes,Found contaminated power steering fluidPressure at idle speed - 80psiwhich do not match with manufacturer specifications,indicating some internal issue with steering rack andpinion or pump hoses.No cracks found and no blockagesNot found any cracks, missing, damages

No accidental damages or bents accepted.No looseness, play, no damages.No excessive movementNo damages, No missing bushesReplace periodically. Test at every service ifit is contaminated. If yes, replace.Engine at idle condition1500kPa(15kgf/cm², 217 psi)No blockage, No bulgesNo missing, damages, cracks.



Analysis of results:

Reason for component and /or system failure

Hydraulic power steering rack and pinion assembly - found no play between pinion and rackObserved fluid leak at steering rack pinionPressure test results do not match with manufacturer specifications. It is indicating internal issues with steeringrack and pinion.

Due to the contaminated power steering fluid, Internal seal leaks or damage.

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Repair recommendations (Recommendation should also include parts to be used)

Replace the Steering rack assembly.Replace the power steering fluid and perform pressure test




Student name




Date of observation

Vehicle (Simulated) – 3: Analyse fault in light vehicle steering system



Research specifications related to light vehicle Steering system from a range of sources

Yes No


Yes No

Identify the hazards related to the task

Yes No


Yes No



Yes No


Yes No


Yes No


Yes No


Yes No


Neeraj SAINI

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Prepare the vehicle for diagnosis

Yes No


Yes No

Carryout system failure analysis

Yes No

Carryout component failure analysis

Yes No


Yes No

Assess the findings and results against evaluation criteria

Yes No

Identify the actual fault and arrive at conclusion

Yes No

Performs further research of technical support information Yes No


Yes No


Yes No


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Yes No


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Specification with regard to steering system wasresearched from bulletins, manufacturer specifications,workshop manuals and repair manuals.Properly managed risks by avoiding jewellery. Removedbattery negative terminal while working with electricalsystems. Used shock proof gloves while working.Concentrated on the work without any distractions.Manufacturer repair manuals and service bulletins wereused to select appropriate symptom based chart.Inspect the noise, steering pump belt, fluid pressure, andpressure sensors. Inspected loose, damaged and worntie-rod ends. Inspected steering gear insulators.Diagnosed steering column for any damage. Inspectedloose suspension bushings, bolts or ball joints.Inspected the fluid for any metal particles in it.Prepared analysis report and specified analysis andevaluation process.

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Yes No


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Assessor Name:



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