Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Basic mechanic's toolbox | Complete petrol engine with visible lubrication system components |
| Flashlight | Lubrication system schematic diagram |
| Inspection mirror | |
| Note book and pen |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Complete petrol engine with visible lubrication system components | 1 Set per Candidate |
| 2 | Basic mechanic's toolbox | 1 Set per Candidate |
| 3 | Flashlight | 1 Pc per Candidate |
| 4 | Inspection mirror | 1 Pc per Candidate |
| 5 | Lubrication system schematic diagram (printed A4) | 1 Pc per Candidate |
| 6 | Note book and pen | 1 Set per Candidate |
| 7 | Overalls/dust coat | 1 Pc per Candidate |
| 8 | Safety boots | 1 Pair per Candidate |
| 9 | Safety gloves | 1 Pair per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Preparation and PPE | |||
| Wore personal protective equipment: overall/dust coat (Award 1 mark or zero) | 1 | ||
| Wore personal protective equipment: safety boots (Award 1 mark or zero) | 1 | ||
| Wore personal protective equipment: safety gloves (Award 1 mark or zero) | 1 | ||
| Sub-Total | 3 | ||
| TASK 2: Identification of lubrication system components | |||
| Identified the oil pump correctly on the engine (Award 2 marks or zero) | 2 | ||
| Identified the oil filter correctly (Award 2 marks or zero) | 2 | ||
| Identified the oil strainer/pick-up correctly (Award 2 marks or zero) | 2 | ||
| Identified the oil gallery/pipe correctly (Award 2 marks or zero) | 2 | ||
| Identified the oil pressure relief valve correctly (Award 2 marks or zero) | 2 | ||
| Sub-Total | 10 | ||
| TASK 3: Explanation of component functions | |||
| Explained the function of the oil pump (Award 2 marks or zero) | 2 | ||
| Explained the function of the oil filter (Award 2 marks or zero) | 2 | ||
| Explained the function of the oil strainer/pick-up (Award 2 marks or zero) | 2 | ||
| Explained the function of the oil gallery/pipe (Award 2 marks or zero) | 2 | ||
| Explained the function of the oil pressure relief valve (Award 2 marks or zero) | 2 | ||
| Sub-Total | 10 | ||
| TASK 4: Safety and housekeeping | |||
| Observed safety during inspection (Award 1 mark or zero) | 1 | ||
| Cleared and organized working area after task completion (Award 1 mark or zero) | 1 | ||
| Sub-Total | 2 | ||
| PRODUCT CHECKLIST | |||
| Correct identification of all five lubrication system components (Award 1 mark each for correct identification x 5 = 5 Marks) | 5 | ||
| Clear and accurate explanation of each component's function (Award 1 mark each for accurate explanation x 5 = 5 Marks) | 5 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 35 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Spanners | Engine oil SAE 10W-30 |
| Screwdrivers | Paraffin |
| Pliers | Cotton waste |
| Socket set | Overalls/dust coat |
| Feeler gauge set | Safety boots |
| Micrometer | Gloves |
| Vernier caliper | |
| Funnel | |
| Drain pan |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Complete petrol engine with rotary oil pump installed | 1 Pc per Candidate |
| 2 | Complete toolbox with spanners, screwdrivers, pliers, socket set | 1 Set per Candidate |
| 3 | Feeler gauge set | 1 Set per Candidate |
| 4 | Measuring micrometer (0-25mm) | 1 Pc per Candidate |
| 5 | Vernier caliper (0-150mm) | 1 Pc per Candidate |
| 6 | Cotton waste | 100 g per Candidate |
| 7 | Paraffin (cleaning solvent) | 0.5 litre per Candidate |
| 8 | Engine oil (SAE 10W-30, petrol engine) | 5 litres per Candidate |
| 9 | Drain pan for used oil | 1 Pc per Candidate |
| 10 | Funnel | 1 Pc per Candidate |
| 11 | Engine stand or bench | 1 Pc per Candidate |
| 12 | Overalls/dust coat | 1 Pc per Candidate |
| 13 | Safety boots | 1 Pair per Candidate |
| 14 | Gloves (mechanics) | 1 Pair per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Preparation and Safety | |||
| Wore personal protective equipment: overall/dust coat, gloves, safety boots (Award 1 mark each or zero x 3 = 3 Marks) | 3 | ||
| Prepared working area and selected correct tools for the job (Award 1 mark or zero) | 1 | ||
| Sub-Total | 4 | ||
| TASK 2: Removal and Dismantling of Oil Pump | |||
| Drained engine oil into drain pan according to manufacturer’s procedure (Award 2 marks or zero) | 2 | ||
| Removed sump to access oil pump (Award 1 mark or zero) | 1 | ||
| Marked joint parts of drive and driven rotors for reassembly (Award 1 mark or zero) | 1 | ||
| Removed oil strainer assembly (Award 1 mark or zero) | 1 | ||
| Removed oil pump assembly and relief valve carefully (Award 2 marks or zero) | 2 | ||
| Sub-Total | 7 | ||
| TASK 3: Cleaning and Inspection | |||
| Cleaned all parts of oil pump thoroughly using paraffin and cotton waste (Award 2 marks or zero) | 2 | ||
| Cleaned oil passages with compressed air or suitable tool (Award 1 mark or zero) | 1 | ||
| Measured oil pump shaft outer diameter with micrometer (Award 1 mark or zero) | 1 | ||
| Measured shaft tip clearance using feeler gauge (Award 1 mark or zero) | 1 | ||
| Measured side clearance between rotors (Award 1 mark or zero) | 1 | ||
| Measured body clearance within pump housing (Award 1 mark or zero) | 1 | ||
| Inspected relief valve and valve spring for damage or weakness (Award 1 mark each or zero x 2 = 2 Marks) | 2 | ||
| Checked oil strainer for cracks or breakage (Award 1 mark or zero) | 1 | ||
| Sub-Total | 10 | ||
| TASK 4: Reassembly and Testing | |||
| Replaced worn out parts and gaskets according to manufacturer’s specifications (Award 2 marks or zero) | 2 | ||
| Assembled oil pump parts in reverse order of dismantling, ensuring joint marks align (Award 2 marks or zero) | 2 | ||
| Performed simple functional test by dipping pump suction in engine oil and rotating shaft clockwise (Award 1 mark or zero) | 1 | ||
| Installed oil pump back into engine correctly (Award 2 marks or zero) | 2 | ||
| Fitted sump and related connectors securely (Award 2 marks or zero) | 2 | ||
| Refilled engine with recommended oil quantity using funnel and checked oil level with dipstick (Award 1 mark or zero) | 1 | ||
| Checked engine and surrounding area for oil leaks after installation (Award 1 mark or zero) | 1 | ||
| Sub-Total | 11 | ||
| TASK 5: Finishing and Safety | |||
| Disposed of used oil according to environmental regulations (Award 1 mark or zero) | 1 | ||
| Cleaned work area and removed oil spillage (Award 1 mark or zero) | 1 | ||
| Observed safety procedures throughout task (Award 1 mark or zero) | 1 | ||
| Completed task within allocated time (Award 1 mark or zero) | 1 | ||
| Sub-Total | 4 | ||
| PRODUCT CHECKLIST | |||
| Oil pump assembly reinstalled correctly without leaks (Award 2 marks or zero) | 2 | ||
| Clearances of shaft, tip, side, and body within manufacturer’s specifications (Award 3 marks or zero) | 3 | ||
| Relief valve and valve spring in good working condition (Award 2 marks or zero) | 2 | ||
| Oil strainer intact without cracks or damage (Award 1 mark or zero) | 1 | ||
| Engine oil level correctly topped up and checked (Award 2 marks or zero) | 2 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 46 | ||