( == »wely higher education == she &training : af Department: Higher Education and Training REPUBLIC OF SOUTH AFRICA T370(E)(J22)T AUGUST EXAMINATION NATIONAL CERTIFICATE DIESEL TRADE THEORY N2 (11040192) 22 July 2014 (Y-Paper) 43:00-16:00 ‘This question paper consists of 5 pages. ‘copyught renewed Please tum over1040182) 2 ‘Tavoceys22)7 DEPARTMENT OF HIGHER EDUCATION AND TRAINING REPUBLIC OF SOUTH AFRICA NATIONAL CERTIFICATE DIESEL TRADE THEORY N2 TIME: 3 HOURS MARKS: 100 INSTRUCTIONS AND INFORMATION Answer ALL the questions, 2. Read ALL the questions careful, 3. Number the answers according to the numbering stem used in tis question paper. 4. Wirlte neatly and legibly. Copritt reserved Please turnover1040109), o ‘rero(e\t22)t QUESTION 1 rr ‘Thete are two main types of Compression lgntion (Cl) engines, namely Direct Injection models and Indirect Injection models. 1.4.4 State THREE advantages of Direct Injection engines compared to Indirect Injection engines. 1.1.2 State THREE disadvantages of Direct Injection engines compared to Indirect injection engines. @ 8 @ “ @ 20) 1.2 Draw a neat labelled sketch of a fuel-supply system that is used on four- cylinder diesel engines. Include the following components in the sketch Fuel tank, Fuel supply pipe, Water trap fter, Low pressure {uel lit pump, ‘Secondary fiter, Primary fiter, High pressure,uel inés.and Injectos 1.3 Name FOUR types of fue itr materials Used in diesel fuel systems, 4.4 Stale TWO functions of the copper washer that. is filed between the injector and the cylinder head ‘QUESTION 2 FIGURE 1 shows a synchtiising Ut Refer to the figure and answer the questions: UC. AYP ES FIGURE 1 21 Name this synchronising unit 22 List the labelled parts (A-H) in your ANSWER BOOK Copyriht reserved Passe turnover a ®(040192) + raro(eys22)T 2.9 Explain the operation ofthis synchronising unit during gear changirg, 6 24 State FOUR functions of a gearbox. ® 2.5 Stata ONE function of the following: 25.1 Interlocking mechanism a 252 Locking mechanism 0) (0) ‘QUESTIONS 3.1 State FOUR safety requirements of a steering mechanism, “ 2.2 Give TWO reasons why the correct castor angle is'a nedessity, a) 3.3 Show, by means of TWO labelled sketches; the iference Between a positive castor and a zero castor. @) 34 Name FOUR types of steering boxes used on light vehicles. @ 3.5 Name the TWO types of wheel balancing methods 2 0) QUESTION 4 FIGURE 2 below shows a fifa diveland éifterential assembly. Refer to the figure and:answer the questions: FIGURE 2 Copyriht reserved Pease turn over(1040192) & “Tere \u22T 4,1 Ust the labelled parts (A-H) in your ANSWER BOOK. @ 4.2 Explain the power flow through this assembly when the vehicle is moving forward, “ 43 State TWO advantages and two disadvantages of 43.1 Semiioating rear axles ® 432 Fully floating rear axles, @ po JON 5.1 Bleeding of a braking system can be described ashe removal ofr from the system, Explain the procedure to be folowed when bleeding the Brakes in a hydraulic brake system. © 5.2 Asa diesel mechanic itis importantio idenity problems in a braking system. Give THREE reasons for each ofthe following common brake problems that ‘may occur on a vehicle: 5.2.4 Excessive brakd'pedal tes play 0 522 Spongy brake pedal °@ 523 Dragging brakes ° 53 Name TWO types dfbrake calipers @ 5.4 Slate THREE propertos of a good hydraulic brake tid @ 20) TOTAL: 100 Copyright reservedhigher education & training Department: Higher Education and Training REPUBLIC OF SOUTH AFRICA MARKING GUIDELINE NATIONAL CERTIFICATE AUGUST EXAMINATION DIESEL TRADE THEORY N2 22 JULY 2014 ‘This marking guideline consists of 7 pages. Copylghtvserved Pease tum overMARKING GUIDELINE 2 ‘rora(eys22)7 DIESEL TRADE THEORY Nz QuESTION1 14 14.1 Advantages of a direct injection engine: + Easier staring because less heat is lost during compression stroke" + Glow plugs are not required for cold starting” © Increase thermal efficiency results in relatively lower fuel ‘consumption Disadvantages of direct injection engine: + Due to increase mean effective pressure, combustion knock ‘may occur more frequertly and be more pronounced” + Increase injection pressure places more stress on the injector pump @ ‘Advantages of indirect injection engine: + The engine can attain higher revolutions and develop more power” ‘+The engine operation s smoother and less noisy.” ‘© Alower grade of fuel may be used” ‘Advantages of indirect injection engine: ‘Starting problems are experienced when engine is ook @ 1.2 FUEL-SUPPLY SYSTEM Copyright reserved Please win oveeMARKING GUIDELINE a ‘Tero(e\22IT DIESEL TRADE THEORY No ‘A= Fuel tank B = Fuel supply pipe C= Water wap titer” 3 pressure fuel ft pumpy secondary fter” = Primary titer igh pressure fuel injection pump ‘ol pump timing gear Leak of pipes” = Injectors igh pressure fuel ines” 1 mark per label (any 6 labels + skete » @ 1.3.» Papermachéy * Porous porcelain” ‘Metal plates tightened to each other or wire mesh @ 1.4 * Tocconduct heat away from the injector tio ‘+ To form a gastight seal between the injector and the cylinder heady @ 1.5 Air has a lower density than diesel, i moves up and by placing tne bleeding ‘Screws atthe top so that all the air can be bled out easly. a) po ‘QUESTION 2 2a C= Sinchro sleevev D = Sinchro hub E = Selector fork F =Detent bail” G = Datant springy H-=Thicd gear ® 22 Constant loading sinchronising unt. 0 2.3 The three springs in the sinchro hub is forcing three stoe! balls ina groove in the middle of the sliding sleeve and the hub has tapered recesses at the fends. When the gear lever moves the selector shat the shaft moves the Selector fork and the fork which fits In the outer groove of the siding sleeve ‘moves the sliding sleeve in the direction of the chosen gear.” Due to the fact that the balls are preventing the sliding sleeve to slide axially in grooves the sliding hub moves with the sliding sleeve until the taper end of the sliding hhub came in contact with the taper face of the gear which cause friction between the sliding hub and the gear, by increasing the pressure on the goar jover, the pressure between the sliding hub “and the gear wil increase resulting in increasing the revolutions of the gear to be selected. When the revolutions of the gear and the sleeve became the same the sieeve will sip ‘over the dogteeth ofthe gear and the gear is selected.v 6 Conyiht eserves Please tan over[MARKING GUIDELINE 24 25 4 DIESEL TRADE THEORY Ne + Obtains a gear reduction to enable the vehicle to pull away from rest. ‘Enables the vehicle to move at high speed while engine is rotating at low revolutions. + Consists of a neutral gear that enables the engine and gearbox to sisconnect from each other.” ‘+ Enables the vehicle to move backward while the engine is rotating. (ny relevant answers) 25.1 Interlocking mechanism: Prevents two goars to be selested simultaneously. 2.6.2 Locking machanism: Prevents jumping out of gear on 2 gearbox.” (ext) ‘QUESTION 3 3A 32 33 Copyciht reserved must be light and easy to contol. The steering mechanism must be fre trom vibration and road shocks. I must be Self-centering” and bring the wheels back to a straight position after making a turn. Suspension and braking must have litle effect on a good steering system. (Any relevent answers) + To ensure that the steering wheel tums lightly and with the same effort in both directions. “+ To prevent the steering wheel from picking up road shocks on uneven ground surfaces. (Any relevant answers) Sa Ca ae at Font A=Wheol” B= Centre line through kingpin C= Gantre line at front of centre of whee! to show postive castor’ D=Kingpiw (Labels: 1 mark each.) (Sketch 4 marks correctness) TavoceyzeyT ) @ (20), © @ ® Presse tun overiiKNG GUIDELINE + rovocey22yt DIESEL TRADE THEORY Ne 84 « Wormand sector ‘= Worm and nut with recirculating balls” = Cam and toler ‘= Cam and lever ‘+ Worm and worm geavrack and pinion (Any3x1) (3) 35 Static balancingy + Dynamic balancing” (2) (20) ‘QUESTION 4 41 Advantages of semiffoating rear axles: = Design is simple. ‘+ Manufacturing cost is comparatively low.“ + Assembly has comparatively low mass.” (Any2x1) 2) Disadvantages of a semi lating rear axe ‘+ Iside shaft breaks between bearing and hub wheel wil fal of. + I side shait breaks between bearing and ciferential, wheel will st and ‘damage brake linings or shoes.” ‘+ To remove or replace a side shalt, vehicle must be raised and wheel removed.” (Any2x1) (2) ‘Advantages ofa fly floating rear axle: ‘+The bearings are set at a fair distance apart from each other, thus the load Is distibuted over a large area. Enables hub to carry a large massy” ‘+ The axle shaft carries no mass.” + Axle shaft can be removed without raising the vehicle and removing the wheel.” + Ifthe axle is broken the vehicle can sill be towed on all four wreels. (Any2x1) Disadvantages ofa fully floating rear axle + Mass more than semi-loating rear axle + Design is complicated. Cost to manufacture is higher.” (any2x1) Copyightresved Please tum overMASKING GUIDELINE s Tere (see) DIESEL TRADE THEORY No 42 A= Side shaft left hand side B= Sun gear LHS C= Planetary gear cross pin D = differential carer bearings E =Crown wheel carter bots. F = Crown wheel G= Pinion H = Thrust washers |= Planetary gears J= Differential carrier K=Carrier bearing cup [L= Sun gear Right hand side M.= Side shaft Right hand side anyaxt) — @) 4.3 The pinion drives the crown wheel and carrier that are bolted together. The ccariet is rotating the differantial cross pin in a tumbling action and the Planetary gears fit on this cross pin thus can turn on the cross pin. The Planetary gears are meshing with the sun gears that are connected with Splines fo the side shafts.” When moving straight ahead the pinion drives the Crown wheel, carrier and cross pin while the cross pin tumbles the planetary ‘gears thus diving the sun gears, thus the planetary gears and sun gears will Not rotate into each other but wil rotate the side shafls at equal revolutions in the same direction. @ (0) QUESTION 5 5.1 Preparation ‘+ Sulfiiont brake fuid must be availabe. “+ Brake adjustment must be carried out correctly + Reservoir to be kept flat allies. + Check f master cylinder fited with return valve. * If master cylinder is fitted with bleeding nipple, alr frst to be bled trom master cylinder. tanysxt) ‘Connect a bleeding pipe to bleeding nipple furthest from master cylinder, with {ree end of pipe immersed in brake fluid in jar ‘When a relum valve is installed, the bleeding nipple is opened and break pedal is repeatedly applied and released slowly unt no air bubbles is Aischarge from bleeding pipe. The bleeding nipple is closed when the brake pedal is kept applied. When no return valve is installed, the brake pedal is first appiad and only than is the bleeding nipple opened. The bleeding nipple is egain closed before the brake padal reaches the end of its travel. Procedure is repeated Until no air bubbles are discharge through the bleeding pipe. @ ‘Cop reserved Please tum over[MAPKING GUIDELINE 53 54 DIESEL TRADE THEORY Ne 5.2.1 Excessive brake pedal free play + Brake shoe adjustment required » Excessive free play between brake pedal and pushrod, or ‘pushrod and piston in brake master cyinder” + Insufficient brake fluid in reservoir (Any 3x1) 522 Spongy brake pedal * Airin the brake system * Brake shoes need adjustment” + Brake drum is cracked + Brake drum or brake shoes may be oval” (Any 3x1) 5.2.3 Dragging Brakes: * Too tight adlusted hand brakev + Problems with master eyinder” ‘+ Brake fuid contamination” + Vent hole blocked on reservoir cap (Any 3x1) Fixed caliper” Floating caliper Must be resistant to freezing Must be resistant to evaporation” Have a high boiling pointy Be resistant to clogging” Bo free of acids Not have a detrimental effect on rubbers” ‘Must lubricate moving parts” Have low viscosity Be hygroscopics/” (Any 3x 1) TOTAL: Teroqeys22yT @ @ ® @ ° oy 100