Professional Documents
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Trinity College
Australia
Practical
Assessment 2 Practical
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
I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their Yes / No
website at (Insert Website Link)
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 Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link)
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
Student Declaration: - I verify that the work completed Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the explained and negotiated the assessment tasks with the
assessment process prior to commencing this student prior to commencing assessment.
assessment task.
Task/s to be To complete this written assessment, you will need to answer the 56 questions comprising
assessed of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.
Location This theory assessment will be completed in a classroom under the supervision of a
trainer/assessor.
Decision making To receive a ‘satisfactory’ outcome for this assessment, students MUST successfully
rules 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 will not have satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
Methods to locate and interpret information required to select and use bearings,
seals, gaskets, sealants and adhesives:
o Manufacturer specifications, procedures and supporting information for
preparing, inspecting and installing sealants and adhesives
o Manufacturer specifications, procedures and supporting information for
preparing, inspecting and installing bearings, seals and gaskets
Workplace procedures required to select and use bearings, seals, gaskets, sealants
and adhesives, including:
o Establishing the serviceability of tools and equipment
o Documentation procedures
o Housekeeping procedures, including:
- Examination of tools and equipment
- Storage of equipment
- Identification, tagging and isolation of faulty equipment
- Disposal of excess materials
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Australia
Practical
- Recycling procedures
Workplace health and safety (WHS) requirements relating to selecting and using
bearings, seals, gaskets, sealants and adhesives, including:
o Procedures for working safely with sealants and adhesives, lubricants and
greases
Environmental requirements relating to selecting and using bearings, seals,
gaskets, sealants and adhesives, including:
o Procedures for trapping, storing and disposing of excess materials
produced when applying sealants and adhesives
o Procedures for trapping, storing and disposing of lubricants and greases
released during work processes
Identification and function of:
o Bearings, including:
- Ball
- Roller
- Plain
o Seals, including:
- Lip
- Face
- O-Ring
- Square section ring
- Metal surface
o Gaskets, including:
- Treated paper
- Cork
- Composite materials
- Metal, synthetic, rubber, fibre, and nylon
Types, characteristics, uses and limitations of sealants and adhesives, including
application techniques
Inspection, service, installation and adjustment procedures, including:
o Bearings, including:
- Roller types
- Ball types
- Plain types
o Seals and sealing surface condition
o Gaskets
Types and applications of bearing lubricants and greases
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Results/Re- The Assessor will grade the assessment and record the result on the front page of
assessment 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 (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
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 If the participant is unable to undertake the written assessment as designed, an interview
Adjustment (verbal questioning) may be used as an alternate approach.
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Assessment 1 – Questioning
Written Assessment
1. Identify five (5) important items of personal safety when working with bearings, seals, gaskets, sealants,
adhesives lubricants and greases.
1 Ear Protection
2 Skin Protection
3 Clothing
4 Footwear
✘ True or False
✘ True or False
✘ True or False
✘ True or False
✘ True or False
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✘ True or False
8. Referring to the LOCTITE® SUPERFLEX® Blue RTV Silicone Adhesive Sealant Safety Data Sheet (SDS),
how should this sealant be trapped, stored and disposed of?
Trapped: Keep the product away from waterways and sewage systems.
As much garbage as you can assemble. For significant spills, have great ventilation going.
Scrap material must be placed in a well-ventilated environment to cure into rubber.
Disposed: According to EPA and municipal rules, cured rubber may be burned or dumped in a landfill.
Observe the disposal requirements of all municipal, state, federal, and provincial legislation.
A. Drain pan.
B. Mop bucket.
C. Storm water drain.
D. Funnel.
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11. When handling, trapping, storing and disposing of new or waste lubricants, grease or sealants and adhesives,
which document should you use to find this information?
Safety Data Sheet (SDS)
1 Needle thrust
2 Straight assembly
3 Loose needle
4 Caged needle
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20. Name the ten [10] engine assembly gaskets, seals and grommets below.
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A. Double-lip seal.
B. Lip-type seal.
C. Metal face seal.
D. Flat seal.
A. Lip seals.
B. Face seals.
C. O-rings.
D. Square section ring.
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When the application circumstances exceed the polymer seal's predefined bounds, a metal seal is utilised. The
pressure is the same and the temperature is either too high or too low.
A. Compressed.
B. Enlarged.
C. Sealed.
D. Friction.
An oil scroll is a spiral groove that is machined in a shaft. The scroll is not the main seal, but it is used to
reduce the amount of oil that reaches the main seal.
The scroll winds in a direction opposite to the shaft rotation. Oil that is carried along the shaft to the scroll
tends to be wound back along the shaft and so retained in the housing.
This is a dished washer that is sometimes used on a shaft where it fits through a housing. Oil reaching the
slinger tends to work outward to the edge of the slinger and is then thrown back away from the shaft.
This is also a supplementary seal and not a main seal. It reduces the quantity of oil that reaches the main
seal.
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Plain gaskets:
These gaskets are made of cork, special jointing sheets, cork, synthetic rubber, and other sheet materials.
Layered gaskets:
These are constructed from two thin sheets of steel and a layer of composition material.
Bonded gaskets:
The gaskets that are affixed to the perforated metal core are made from composition materials. Typically, metal
ferrules are used to strengthen the holes in the gasket.
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1 Thread sealants
3 Gasket sealants
5 Retaining compound
Missing Words: air, assembly, bearing, bolts, component, cylinder, fluid, gasket, leaking, liquids, loose, rocker,
sealant, silicone, strengths, threads, wear
1 Thread sealants. Sealants are applied to threads to prevent fluid under pressure from leaking past the
thread. They are commonly used on bolts that come into contact with the cooling system, such as cylinder
head bolts.
2 Thread lock compounds. These prevent nuts, bolts and studs from coming loose and are available in
various grades or strengths. They work by filling in the small gaps between the threads with a fluid that
cures or ‘sets’ in the absence of air. This is known as anaerobic cure. They are useful for fasteners that
cannot be checked after assembly, such as flywheel bolts.
3 Gasket sealants. Some gaskets are coated with a sealant just prior to assembly. This fills the small
spaces between the component and the gasket. The sealant is normally applied to the removable part, for
example, between the rocker cover and the gasket. They also help to keep the gasket in place during
assembly.
4 RTV silicone sealants. These silicone sealants cure or vulcanise at room temperature (RTV). They can be
used in place of a gasket to produce formed-in-place gaskets.
5 Retaining compounds. These are anaerobic liquids that can be used for applications such as between the
inner race of a bearing and its shaft, or between the outer race of the bearing and its housing. This
secures the bearing in place and compensates for any minor wear in the parts. Catalytic action between
the parts assists with curing.
✘ True or False
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Gasket adhesives form a tough bond when used on clean, dry surfaces. Adhesives do not aid the sealing
ability of the gasket. They are meant only to hold gaskets in place during assembly. Use small dabs. Do not
assemble components until the adhesive is completely dry.
37. Explain the four (4) steps needed to clean and check a ball or roller bearing assembly?
1 Use a solvent to clean the bearings, then allow them to air dry. It could be necessary to soak oily bearings.
3 Slowly rotate the bearing by hand to inspect it for any irregularities. Put force in the thrust direction by using
thrust bearings.
4 Check for flaws in the bearing surfaces, balls, and rollers. Rotate the bearing carefully inspecting each
surface as you go.
39. Describe briefly how front-wheel bearings of a rear wheel-drive vehicle would be adjusted.
Once completely tightened, the nut is backed off by about a sixth of a turn.
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✘ True or False
✘ True or False
A. Treat gaskets with care to avoid damage; carelessness can ruin a new gasket before it is used.
B. The surfaces of the parts against which the gasket seats should be clean, with all traces of the old gasket
removed.
C. Cast-iron and aluminium alloy surfaces can be checked for flatness, and burrs can be removed by lightly
draw-filing them with a smooth flat file or carefully rubbing them with fine-grade wet and dry sandpaper.
D. Where a gasket is fitted between two parts, the bolts that hold the parts should be tightened one at a time.
A torque wrench should be not used to tighten the bolts.
Missing Words: corrosion, damage, grease, lithium, lube, materials, petroleum, soaps
The grease for wheel bearings should be smooth textured, consist of soaps and oils, and be free of filler and
abrasives. Recommended are lithium complex (or equivalent) soaps, or solvent-refined petroleum oils.
Additives could be added to inhibit corrosion and oxidation. The grease should be noncorrosive to bearing
materials with no chance of separating during storage or use.
Using the correct amount of lube is also essential. Failure to maintain proper lubrication might result in
bearing damage, causing a wheel to lock.
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✘ True or False
✘ True or False
✘ True or False
✘ True or False
✘ True or False
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A. Copper.
B. Steel.
C. Both “Copper” and “Steel”.
D. Neither “Copper” and “Steel”.
✘ True or False
52. You are refitting the engine oil pan sub-assembly on a 2007 FJ Cruiser. Referring to the 2007 FJ Cruiser
Engine Mechanical Workshop manual, locate and interpret the sealant type recommended by Toyota, and
sealant application and width instructions, including the time engine oil pan sub-assembly MUST be fitted
within.
Sealant type recommended by Toyota: Toyota Genuine Seal Packing Black, Three Bond 1207B or the equivalent
Sealant application and width instructions: Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12
to0.16 in.)) to the oil pan
Sealant instructions: Three minutes after applying the seal packing, install the oil pan. Tighten the bolts and nuts
within 15 minutes of installing the oil pan. If not, the seal packing must be removed and then reapplied.
53. You are refitting the engine cylinder head after replacing the head gasket on a 2007 FJ Cruiser. Referring to
the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the cylinder head bolt torque
specifications.
1st 36Nm, 367kgf*cm or 27ft*lbf
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54. You are refitting the engine cylinder head after replacing the head gasket on a 2007 FJ Cruiser and you need
to refit cooling system unions. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate
and interpret the cooling system unions adhesive type recommended by Toyota application and width
instructions specifications.
Adhesive type recommended by Toyota: Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent
Sealant application and width instructions: Apply adhesive to 2 to 3 threads of the bolts end.
55. You are refitting the engine crankshaft pulley after replacing the timing gear case oil seal on a 2007 FJ
Cruiser. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the
crankshaft pulley bolt torque specifications.
250Nm, 2,549kgf*cm or 184ft*lbf
56. You are refitting the rebuilding the engine on a 2007 FJ Cruiser and have replaced connecting rod big end
bearings. Referring to the 2007 FJ Cruiser Engine Mechanical Workshop manual, locate and interpret the
connecting rod end cap bolt torque specifications.
1st 25Nm, 259kgf*cm or 18ft*lbf
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