otomotiv

Competitor

Name

Country

Code

Marking

Scale

Engine Mechanical

Toolbox berisi Hand Tool set yang harus dibawa oleh peserta lomba dengan isi antara lain :

1 set kunci Ring Pass Kombinasi. ( 8 – 22 )
1 set kunci Pass. ( 8 – 22 )
1 set kunci sock. ( 8 – 22 )
1 set Obeng.
1 tang kombinasi.
1 tang buaya.
1 tang pipa.
1 tang kabel.
1 mistar sorong.
1 lampu kontrol.
1 penggaris baja.
1 set fuller gauge.
1 set kunci " L ".
1 palu besi.
1 palu plastik.
1 penggores.
1 kunci busi.
1 set center punch.

Panitia Lomba tidak menyediakan Toolbox dengan isi seperti tersebut diatas maka diwajibkan untuk peserla lomba membawah sendiri sendiri.

Panitia Lomba

=============================================================================================

PROMOSI KOMPETENSI SISWA(PKS)

SEKOLAH MENENGAH KEJURUAN

TINGKAT NASIONAL KE XII - 2004

BIDANG LOMBA

OTOMOTIF

DEPARTEMEN PENDIDIKAN NASIONAL

DIREKTORAT JENDERAL PENDIDIKAN DASAR DAN MENENGAH

DIREKTORAT PENDIDIKAN MENENGAH KEJURUAN

2004

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		A

Competitor Instructions

Task A

Petrol Engine Tune

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary

Section		Possible Mark
1.	Preparation.	180
2.	Repair engine to start and run.	250
3.	Correct and repair drivability problem.	200
4.	Use of the exhaust gas analyser.	160
5.	Checks and measurements of fuel injectors.	280
6.	Check the coolant temperature sensor.	50
7.
8.
9.
Task Total		1120

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remark: Vehicle/model : KIA Sephia ( TIMOR )

Competitor Name	Country Code	Task
		A

1.	The engine will not run! Before this problem the engine had rough operation and high fuel consumption.
2.	The vehicle recently left the repair shop, and now it seems to be worse!
3.	You may use tools and equipment you have, and is provide for you to diagnosis and repair problems found.
4.	Ask the judge for repair-parts needed and show him what you have found.
5.	After the engine is running satisfactory and no trouble codes are present, proceed to the items listed below:
6.	Check the exhaust emission using the Emission Analyzer and record your findings.
7.	Check the coolant temperature sensor using tech.2 and record your findings.
8.	Note : Do not try to repair a defective part! (Ask first)
9.
10.

Form 5 – Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		A	Petrol Engine Tune

Marking Summary

Section		Possible Mark	Actual Mark
1.	Preparation.	180
2.	Repair engine to start and run.	250
3.	Correct and repair drivability problem	200
4.	Use of the exhaust gas analyser.	160
5.	Check and measurements of fuel injectors.	280
6.	Check the coolant temperature sensor.	50
7.
8.
9.
10.
Task Total		1120

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1	2	3	4

Competitor Name	Country Code	Task	Marking Scale
		A	Petrol Engine Tune

1.	Preparation	Yes	No	Actual	Comments
1.1	Checked all equipment first	10	0
1.2	Checked all instructions	10	0
1.3	Selected the correct test equipment	20	0
1.4	Used logical working procedure	10	0
1.5	Connected the exhaust hose	10	0
1.6	Proper tools handling	10	0
1.7	Correctly used the exhaust analyzer	10	0
1.8	Checked oil level	10	0
1.9	Checked water level	10	0
1.10	Clean up the working area	10	0
1.11	Clean up tools and equipment	10	0
1.12	Clean up the test models	10	0
1.13	Choked tires	10	0
1.14	Used fender covers	10	0
1.15	Used seat covers	10	0
1.16	Used steering wheel cover	10	0
1.17	Used floor matt	10	0
1.18
1.19
1.20
Sub-Total		180	0

2.	Repair Engine to Start & Run	Yes	No	Actual	Comments
2.1	Checked fuel pump fuse 20 A (main fuse)	30	0
2.2	Reinstal fuel pump fuse	25	0
2.3	Check fuel injector connector (x 22) loses	50	0
2.4	Check injectors electrical connection	50	0
2.5	Using scan tool	45	0
2.6	Using service manual correctly	50	0
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
Sub-Total		250	0

Competitor Name	Country Code	Task	Marking Scale
		A	Petrol Engine Tune

3.	Correct & Repair Drivability Problem	Yes	No	Actual	Comments
3.1
3.2	Check and find defect sensor	40	0
3.3	Diagnosis use scan tool	60	0
3.4	Install loose connector	40	0
3.5	Clear the codes	40	0
3.6	Reinstall the removed parts	20	0
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
Sub-Total		200	0

4.	Checks & Measurement of Fuel Injector	Yes	No	Actual	Comments
4.1	Remove fuel injector connectors with care	20	0
4.2	Set test equipment to Ohms	20	0
4.3	Correct measurement of injector 1 ohm	20	0
4.4	" 2	20	0
4.5	" 3	20	0
4.6	" 4	20	0
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
Sub-Total		160	0

Competitor Name	Country Code	Task	Marking Scale
		A	Petrol Engine Tune

5.	Use of the Exhaust Analyzer	Yes	No	Actual	Comments
5.1	Set up gas analyzer	40	0
5.2	Allow engine idle speed to stabilize	20	0
5.3	Measured CO reading	25	0
5.4	" CO2 reading	25	0
5.5	" O2 reading	25	0
5.6	" HC reading	25	0
5.7	Set engine to 2500 rpm	20	0
5.8	Measured CO reading	25	0
5.9	" CO2 reading	25	0
5.10	" O2 reading	25	0
5.11	" HC reading	25	0
5.12
5.13
5.14
5.15
Sub-Total		280	0

6.	Check the Coolant Temperature Sensor	Yes	No	Actual	Comments
6.1	Check loose connector	25	0
6.2	Measure resistance	25	0
6.3
6.4
6.5
Sub-Total		50	0

Name	#	Country	abbr.	task:	task#
……………………	…..	………………	……..	Engine Tune	A

Report Form

Task A Diagnosing and Engine Tuning-up

S/No	Items	Performance/ Condition of Components
S/No	Items	Good	Bad
1.	Fuel Injector Inspection Resistance Injector No 1 __________ Ohms Injector No 2 __________ Ohms Injector No 3 __________ Ohms Injector No 4 __________ Ohms
2	Exhaust Emission Test Idling Speed CO reading ________________ % CO2 reading ________________ % O2 reading ________________ % HC reading ________________ ppm At 2,500 rpm CO reading ________________ % CO2 reading ________________ % O2 reading ________________ % HC reading ________________ ppm

Name	#	Country	abbr.	task:	task#
……………………	…..	………………	……..	Engine Tune	A

Report Form DE

Report form

(2 of 2)

S/No	Items	Performance/ Condition of Components
S/No	Items	Good	Bad
3	Coolant Temperature Sensor Sensor Standard Temperature Resistance Resist spec. 80 degrees C ________ Ohm _______ Ohm

========================================================================

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		B

Competitor Instructions

Task B

Brake System

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary

Section		Possible Mark
1.	Preparing	160
2.	Servicing the Service Brake Mechanical System	500
3.	Measuring the Mechanical Brake Component	100
4.	Adjusting the Parking Brake Mechanical	140
5.
6.
7.
8.
Task Total		1400

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remark: Vehicle/model: Toyota Kijang

Competitor Name	Country Code	Task
		B

1.	Perform service work on the brake mechanical system
2.	Rectify the cause of excessive parking brake pedal travel distance
3.	Fill in the mechanical section report sheet as your work
4.	Use safe and clean working practice at all times
5.
6.
7.
8.
9.
10.

Form 5 – Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		B	Braking Systems

Marking Summary

Section		Possible Mark	Actual Mark
1.	Preparing	160
2.	Servicing the Service Brake Mechanical System	500
3.	Measuring the Mechanical Brake Component	100
4.	Adjusting the Parking Brake Mechanical	140
5.
6.
7.
8.
9.
10.
Task Total		1400

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1	2	3	4

Competitor Name	Country Code	Task	Marking Scale
		B	Braking Systems

1.	Preparation	Yes	No	Actual	Comments
1.1	Check all equipments	10	0
1.2	Check all instructions	10	0
1.3	Apply logical working procedure	10	0
1.4	Proper tools handling	10	0
1.5	Clean up the working area	10	0
1.6	Clean up tools and equipment	10	0
1.7	Clean up the test models	10	0
1.8	Ramp, lowered onto stops	10	0
1.9	Jacks, pads used	10	0
1.10	Jacks, pads positioned correctly	10	0
1.11	Parking brake applied at end	10	0
1.12	Choke tires	10	0
1.13	Use fender covers	10	0
1.14	Use seat covers	10	0
1.15	Use steering wheel cover	10	0
1.16	Use floor mats	10	0

Sub-Total			0

2.	Servicing the Service Brake Mech. System	Yes	No	Actual	Comments
2.1	Use workshop manual	30	0
2.2	Dismantle disc brake (FR)	30	0
2.3	Check component for damage	30	0
2.4	Measure disc thickness	30	0
2.5	Install disc to hub	30	0
2.6	Adjust wheel bearing	30	0
2.7	Apply grease to the bearing	20	0
2.8	Measure disc for run-out	20	0
2.9	Fit caliper and brake pads	30	0
2.10	Torque caliper bolts	30	0
2.11	Clean all components	30	0
2.12	Dismantle drum brake (RL)	30	0
2.13	Check component for damage	30	0
2.14	Measure Drum	30	0
2.15	Install Drum to hub	30	0
2.16	Measure Drum for run-out	20	0
2.17	Clean all components	30	0
2.18	Install Rear wheel (110 Nm)	20	0
Sub-Total		500	0

Competitor Name	Country Code	Task	Marking Scale
		B	Braking Systems

3.	Parking Brake Adjustment	Yes	No	Actual	Comments
3.1	Use workshop manual	30	0
3.2	Lubricate the linkages	30	0
3.3	Adjust Cable tightness to 9 notch	40	0
3.4	Adjust Cable tightness to ± 5 notch	20	0
3.5	Adjust Cable tightness to ± 7 notch	20	0
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
Sub-Total		140	0

4.	Yes	No	Actual	Comments
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.17
4.18

Sub-Total

Competitor Report Sheet – Automobile Technology

Competitor Name	Country Code	Task
		B

Report Sheet

Task B Measuring Mechanical Brake System ( 100 )

S/No	Items	Performance/ Condition of Components
S/No	Items	Good	Bad
1.	Disc Thickness Thickness Spec.Thickness Front Left __________ mm ________ mm
2	Drum Diameter Diameter Spec.Diameter Rear Right __________ mm ________ mm

==========================================================

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		C (MT)

Manual Transmission

Competitor Instructions

Task C

Transmission (MT)

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary
Section		Possible Mark
1.	Preparation	190
2.	Disassembly Gear Box	70
3.	Assembly Gearbox	140
4.	Part Condition and Measurement	200
5.
6.
7.
Task Total		600

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remark: Suzuki Rear Wheeldrive Transmission

Competitor Name	Country Code	Task
		C (MT)

Automatic Transmission Instruction
1.	Car does not run in "R" positions Do continuity inspections for "R" positions Find out and rectify the fault on the Transmission. Fill in the report sheet.
2.	Disassemble and Assemble the manual transmission on stand.
3.
4.
5.
6.

Form 5 – Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		C (MT)	Transmissions

Marking Summary

Section

Possible

Mark

Section		Possible Mark	Actual Mark
1.	Preparation	190
2.	Disassembly Gear Box	70
3.	Assembly Gearbox	140
4.	Part Condition and Measurement	200
5.
6.
7.
Task Total		600

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1	2	3	4

Competitor Name	Country Code	Task	Marking Scale
		C(MT)	Transmissions

1.	Preparation	Yes	No	Actual	Comments
1.1	Use workshop manual	10	0
1.2	Check all equipments	10	0
1.3	Check all instructions	10	0
1.4	Select the correct test equipment	10	0
1.5	Use logical working procedure	10	0
1.6	Proper tools handling	10	0
1.7	Clean up the working area	10	0
1.8	Clean up tools and equipment	10	0
1.9	Clean up the test models	10	0
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
Sub-Total			0

2.	Vehicle test	Yes	No	Actual	Comments
2.1	Find fault at Parking (R) position	25	0
2.2	Rectify the faults	50	0
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
Sub-Total		75	0

Competitor Name	Country Code	Task	Marking Scale
		C (MT)	Transmissions

3.	Disassembling MT Gear Box (on Stand)	Yes	No	Actual	Comments
3.1	Use workshop manual	20	0
3.2	Remove shift	20	0
3.3	Remove the rear houshing	20	0
3.4	Remove the reverse gear set	20	0
3.5	Remove the upper houshing	20	0
3.6	Remove the Gear set	20	0
3.7	Remove Counter Gear	20	0
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
Sub-Total		140	0

4.	Assembling MT Gear Box (on Stand)	Yes	No	Actual	Comments
4.1	Install the Counter Gear	20	0
4.2	Install the Gear set	40	0
4.3	Install Upper houshing	40	0
4.4	Install theReverse gear set	30	0
4.5	Install rear houshing	20	0
4.6	Install the shift	20	0
4.7	Test the Transmission function	30	0
4.8
	Sub-Total	200	0

Competitor Report Sheet – Automobile Technology

Competitor Name	Country Code	Task
		C (MT)

Report Sheet

Transmission Test

Are the Tranmission have problem ?

Yes No

List bad conditioned parts

Item No.	Bad conditioned components	Remarks
1
2
3
4
5
6
7
8
9
10

=================================================================================

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		D

Competitor Instructions

Task

Engine Mechanical

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary

Section		Possible Mark
1.	Preparation	100
2.	Dismantling Timing Belt	40
3.	Dismantling Cylinder Head	70
4.	Dismantling Piston, Connecting Rod and Crankshaft	100
5.	Cylinder Bore and Piston Measurement	200
6.	Crankshaft and Bearing Measurement	200
7.	Assembling Piston, Connecting Rod and Crankshaft	200
8.	Assembling Cylinder Head, Front Case and Oil Pan	100
9	Assembling Timing Belt	120
10.
11.
Task Total

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remarks : Engine Daihatsu Charade 1,3 L

Form 5 – Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		D	Engine Mechanical

Marking Summary

Section		Possible Mark	Actual Mark
1.	Preparation	100
2.	Dismantling Timing Belt	40
3.	Dismantling Cylinder Head	70
4.	Dismantling Piston, Connecting Rod and Crankshaft	100
5.	Cylinder Bore and Piston Measurement	200
6.	Crankshaft and Bearing Measurement	200
7.	Assembling Piston, Connecting Rod and Crankshaft	200
8.	Assembling Cylinder Head, Front Case and Oil Pan	100
9.	Assembling Timing Belt	120
10.
11.
Task Total		1130

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1.	Preparation	Yes	No	Actual	Comments
1.1	Use workshop manual	10	0
1.2	Check all equipments	10	0
1.3	Check all instructions	10	0
1.4	Select the correct tools	10	0
1.5	Proper tools handling	10	0
1.6	Calibrate measuring tools	10	0
1.7	Use logical working procedure	10	0
1.8	Clean up the working area	10	0
1.9	Clean up tools and equipment	10	0
1.10	Clean up the test models	10	0
1.11
1.12
Sub-Total		100	0

2.	Dismantling timing belt	Yes	NO	Actual	Comments
2.1	Remove crankshaft bolts and pulley	10	0
2.2	Remove timing belt front cover	5	0
2.3	Remove tensioner pulley	5	0
2.4	Remove tensioner arm	5	0
2.5	Remove auto tensioner	5	0
2.6	Remove idler pulley	5	0
2.7	Remove timing belt	5	0
2.8
2.9
2.10
2.11
2.12
Sub-Total		40	0

3.	Dismantling cylinder head		Yes	NO		Actual	Comments
3.1	Remove rocker cover		10	0
3.2	Remove cylinder head bolts in correct order		50	0
3.3	Remove cylinder head gasket		10	0
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
	Sub-Total		70	0
Competitor Name		Country Code			Task			Marking Scale
					D			Engine Mechanical
4.	Dismantling piston, connecting rod and crankshaft		Yes	No		Actual	Comments
4.1	Remove connecting rod bearing cap		25	0
4.2	Remove piston		25	0
4.3	Remove main bearing cap		25	0
4.4	Remove crankshaft		25	0
4.5
4.6
4.7
4.8
Sub-Total			100	0

5.	Cylinder Bore & Piston Measurement	Yes	NO	Actual	Comments
5.1	Measure Outer Diameter Piston No. 1	40	0
5.2	Measure Inner Diameter Cylinder No. 1	40	0
5.3	Measure piston Oil Clearance Cylinder No. 1	20	0
5.4	Measure Roundness Cylinder No. 1	30	0
5.5	Measure Cylindericity Cylinder No. 1	30	0
5.6	Measure Piston ring side Clearance No. 1	20	0
Sub-Total		180	0

6.	Crankshaft & Bearing Measurement	Yes	No	Actual	Comments
6.1	Measure Crank Journal Outer Diameter No. 1	30	0
6.2	Measure Main Bearing Inner Diameter No. 1	30	0
6.3	Measure Oil Clearance Crank Journal No. 1	20	0
6.4	Measure Crank Pin Outer Diameter No. 1	25	0
6.5	Measure Crank Pin Bearing Inner Diameter No.1	25	0
6.6	Measure Oil Clearance Crank Pin No. 1	20	0
6.7	Measure Crank journal out of round No.1	25	0
6.8	Measure Crank shaft journal taper No.1	25	0
6.9
Sub-Total		200	0

Competitor Name	Country Code	Task	Marking Scale
		D	Engine Mechanical

7.	Assembling piston, connecting rod and crankshaft	Yes	No	Actual	Comments
7.1	Assemble crankshaft	40
7.2	Assemble main bearing & cap	30
7.3	Assemble piston ring in correct setting	50
7.4	Assemble piston	40
7.5	Assemble connecting rod bearing & cap	20
7.6	Lubricate components before assembling	20
7.7
7.8
7.9
7.10
Sub-Total		200	0

8.	Assembling cylinder head	Yes	NO	Actual	Comments
8.1	Assemble cylinder head gasket	20
8.2	Lubricate cylinder head bolt	10
8.3	Assemble cylinder head bolts in correct order	60
8.4	Assemble rocker cover	10
8.5
8.6
8.7
8.8
Sub-Total		100	0

9.	Assembling timing belt	Yes	No	Actual	Comments
9.1	Assemble crankshaft bolts	10
9.2	Assemble idler pulley	15
9.3	Assemble auto tensioner	15
9.4	Assemble tensioner arm	10
9.5	Assemble tensioner pulley	10
9.6	Assemble timing belt in the correct position	50
9.7	Assemble timing belt front cover	10
9.8
9.9
9.10
Sub-Total		120	0

Competitor Report Sheet – Automobile Technology

Competitor Name	Country Code	Task
		D

Report Sheet

ENGINE MECHANICAL

Piston

Description

Specification

Actual

Serviceable

Unserviceable

No. 1 Piston Outer Diameter

Cylinder bore

Description

Specification

Actual

Serviceable

Unserviceable

No. 1 Cylinder inner diameter

A1:

B1:

C1:

A2:

B2:

C2:

Roundness Cylinder No.1

Cylindricity Cylinder No.1

A1:

B1:

Piston ring

Description

Specification

Actual

Serviceable

Unserviceable

Piston 1 Side clearance (No. 1 compression ring)

Piston 1 Side clearance (No. 2 compression ring)

Piston 1 End Gap (No. 1 compression ring)

Piston 1 End Gap (No. 2 compression ring)

Crankshaft

Description

Specification

Actual

Serviceable

Unserviceable

Crankshaft & Play

No. 1 Crankshaft journal Outer Diameter

A1:

B1:

A2:

B2:

No. 1 Main Bearing Inner Diameter.

A1:

B1:

A2:

B2:

Oil clearance (No. 1 cylinder)

e) Crank Pin

Description

Specification

Actual

Serviceable

Unserviceable

Connecting rod & play

No. 1 Crank pin journal Outer Diameter

A1:

B1:

A2:

B2:

No. 1 Main Bearing Inner Diameter.

A1:

B1:

A2:

B2:

Oil clearance (No. 1 cylinder)

Competitor Name	Country Code	Task
		D

1.	Perform diagnostic work according to the fault and fill in the report sheet
2.	Prepare all necessity tools and equipment for measuring for measuring engine components.
3.	Perform measurement work according to the report sheet and justify the result.
4.
5.
6.
7.
8.
9.
10.

=================================================================================

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		E

Competitor Instructions

Task E

Charging System

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary

Section		Possible Mark
1.	Preparation	170
2.	Charging system Problem	250
3.	Regolator Problem	240
4.	Measuring	100
5.
6.
7.
8.
9.
Task Total		760

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remark: Engine Stand Toyota 5K

Competitor Name	Country Code	Task
		E

1.	The engine running in normal condition. Inspect and Diagnose the faults Repair as needed.
2.	Check operating of charging system Diagnose if found faulty For repairs refer to the expert Fill in the report form
3.	Check operation of charging control lamp Diagnose if faulty Repair if necessary Fill in report form
4.	Check operation of Alternator Diagnose if faulty For repairs refer to the expert Fill in report form
5.	Measure the Charging Voltage Diagnose if faulty For repairs refer to the expert Fill in report form
6.	Measure the Charging Curren Diagnose if faulty For repairs refer to the expert Fill in report form
7.	Reinstal the fault component Refer to expert before reinstal Fill in report form.
8.
9.
10.

Form 5 - Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		E	Charging System

Marking Summary

Section		Possible Mark
1.	Preparation	170
2.	Engine Cooling system Problem	250
3.	Rear lights	240
4.	Measuring	100
5.
6.
7.
8.
9.
Task Total		760

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1	2	3	4

Competitor Name	Country Code	Task	Marking Scale
		E	Charging System

1.	Preparation	Yes	No	Actual	Comments
1.1	Check all equipments	10	0
1.2	Check all instructions	10	0
1.3	Select the correct test equipment	10	0
1.4	Apply logical working procedure	10	0
1.5	Connect the exhaust hose	10	0
1.6	Proper tools handling	10	0
1.7	Test the lead of multimeter	10	0
1.8	Check oil level	10	0
1.9	Check water level	10	0
1.10	Clean up the working area	10	0
1.11	Clean up tools and equipment	10	0
1.12	Clean up the test models	10	0
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
Sub-Total			0

2.	Charging system Problem	Yes	No	Actual	Comments
2.1	Using workshop manual	30	0
2.2	Check electric circuit and mechanical stuck	30	0
2.3	Set up multimeter to correct position	30	0
2.4	Check field supply for Alternator	30	0
2.5	Check Out put from Alternator	30	0
2.6	Check function of the Regulator	30	0
2.7	Check function of The charging control lamp	30	0
2.8	Problem solved	40	0
2.9
2.10
2.11
2.12
Sub-Total		250	0

Competitor Name	Country Code	Task	Marking Scale
		E	Charging System

3.	Regulator Problem	Yes	No	Actual	Comments
3.1	Check function of the Regulator	30	0
3.2	Check control lamp relay	30	0
3.3	Check voltage regulator relay	30	0
3.4	Check contact point	30	0
3.5	Ask the right parts	30	0
3.6	Install the right part correctly	30	0
3.7	Check function after replacing parts	30	0
3.8	Fit back the parts, problem solved	30	0
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
Sub-Total		240	0

4.	Yes	No	Actual	Comments
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Sub-Total		0

Competitor Report Sheet – Automobile Technology

Competitor Name	Country Code	Task
		E

Report Sheet

1.	Did engine operated normaly? [ ] yes [ ] no Fault(s) found:
2.	Did the charging system operate normaly? [ ] yes [ ] no Fault(s) found:
3.	Did the charging control lamp operate normaly? [ ] yes [ ] no Fault(s) found:
4.	Did the regolator operate normaly? [ ] yes [ ] no Fault(s) found:

S/No	Items	Performance/ Condition of Components
		Good	Bad
5	Charging Voltage by 3000 Rpm ( 50 ) Voltage Standart Voltage ________ V _______ V Charging Current by 3000 Rpm ( 50 ) Current Standart Current ________ A _______ A

================================================================================

Competitor Instructions – Automobile Technology

Competitor Name	Country Code	Task
		F

Competitor Instructions

Task F

Car Body Electrical Systems

Familiarization Time	5 minutes
Task Duration	55 minutes
Total Time	60 minutes

Marking Summary

Section		Possible Mark
1.	Preparation	170
2.	Engine Cooling system Problem	200
3.	Rear lights	200
4.	Internal lights	200
5.	Head light	200
6.	Water supply for windshield system	200
7.
8.
9.
Task Total		1170

You are required to

- Observe occupational health & safety standards

- Only ask necessary questions

- Not speak to the public while competing

- Comply with Experts instructions

- Ensure Name & Country Code on all forms

- Use appropriate tools and procedures

- Complete all instructions on the next page

Remark: Vehicle/Model: Suzuki Katana

Competitor Name	Country Code	Task
		F

1.	The engine running in normal condition. Inspect and Diagnose the faults Repair as needed. Fill in the report form
2.	Check operating of lights system of the car Diagnose if found faulty For repairs refer to the expert Fill in the report form
3.	Check operation of interior lights Diagnose if faulty Repair if necessary Fill in report form
4.	Check operation of head light Diagnose if faulty For repairs refer to the expert Fill in report form
5.	Check operation of windshield cleaning system Diagnose if faulty For repairs refer to the expert Fill in report form
6.
7.
8.
9.
10.

Form 5 - Automobile Technology

Competitor Name	Country Code	Task	Marking Scale
		F	Electrical Systems

Marking Summary

Section		Possible Mark
1.	Preparation	170
2.	Engine Cooling system Problem	200
3.	Rear lights	200
4.	Internal lights	200
5.	Head light	200
6.	Water supply for windshield system	200
7.
8.
9.
Task Total		1170

Time Keeping

Familiarization	Competition	Breaks
Start	Start	Start
Stop	Stop	Stop

Experts Signatures

1	2	3	4

Competitor Name	Country Code	Task	Marking Scale
		F	Electrical Systems

1.	Preparation	Yes	No	Actual	Comments
1.1	Check all equipments	10	0
1.2	Check all instructions	10	0
1.3	Select the correct test equipment	10	0
1.4	Apply logical working procedure	10	0
1.5	Connect the exhaust hose	10	0
1.6	Proper tools handling	10	0
1.7	Test the lead of multimeter	10	0
1.8	Check oil level	10	0
1.9	Check water level	10	0
1.10	Clean up the working area	10	0
1.11	Clean up tools and equipment	10	0
1.12	Clean up the test models	10	0
1.13	Choke tires	10	0
1.14	Use fender covers	10	0
1.15	Use seat covers	10	0
1.16	Use steering wheel cover	10	0
1.17	Use floor matts	10	0
1.18
1.19
1.20
Sub-Total			0

2.	Engine Cooling system Problem	Yes	No	Actual	Comments
2.1	Using workshop manual	20	0
2.2	Check electric fan for continues and mechanical stuck	20	0
2.3	Set up multimeter to correct position	20	0
2.4	Check power supply for electric fan	20	0
2.5	Check water temperator sensor	20	0
2.6	Check fuse	20	0
2.7	Check relay for electric fan	30	0
2.8	Replace correct parts	30	0
2.9	Problem solved	20	0
2.10
2.11
2.12
2.13
2.14
Sub-Total		200	0

Competitor Name	Country Code	Task	Marking Scale
		F	Electrical Systems

3.	Rear lights (tail lights)	Yes	No	Actual	Comments
3.1	Check function of the lights system	20	0
3.2	Check bulbs	20	0
3.3	Check positive circuit	20	0
3.4	Check ground connection	20	0
3.5	Check fuse	20	0
3.6	Use workshop manual	20	0
3.7	Ask the right parts	20	0
3.8	Install the right part correctly	20	0
3.9	Check function after replacing parts	20	0
3.10	Fit back the parts, problem solved	20	0
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
Sub-Total			0

4.	Interior lights	Yes	No	Actual	Comments
4.1	Check function of the lights system	20	0
4.2	Check bulbs	20	0
4.3	Check positive circuit	20	0
4.4	Check ground connection	20	0
4.5	Check fuse	20	0
4.6	Use workshop manual	20	0
4.7	Ask the right parts	20	0
4.8	Install the right part correctly	20	0
4.9	Check function after replacing parts	20	0
4.10	Fit back the parts, problem solved	20	0
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
Sub-Total			0

Competitor Name	Country Code	Task	Marking Scale
		F	Electrical Systems

5.	Water supply for front Wiper	Yes	No	Actual	Comments
5.1	Check fuse	20	0
5.2	Check relay	20	0
5.3	Check ground connection	20	0
5.4	Check positive circuit	20	0
5.5	Check water pump motor	20	0
5.6	Check voltage drop: fuse - wiper motor	20	0
5.7	Used workshop manual	20	0
5.8	Ask the right parts	20	0
5.9	Install the right part correctly	20	0
5.10	Problem solved	20	0
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
Sub-Total			0

6.	Head lights	Yes	No	Actual	Comments
6.1	Check function of the lights system	20	0
6.2	Check bulbs	20	0
6.3	Check positive circuit	20	0
6.4	Check ground connection	20	0
6.5	Check fuse	20	0
6.6	Use workshop manual	20	0
6.7	Ask the right parts	20	0
6.8	Install the right part correctly	20	0
6.9	Check function after replacing parts	20	0
6.10	Fit back the parts, problem solved	20	0
6.11
6.12
6.13
6.14
6.15
Sub-Total		200	0

Competitor Report Sheet – Automobile Technology

Competitor Name	Country Code	Task
		F

Report Sheet

1.	Did engine ovrheating? [ ] yes [ ] no Fault(s) found:
2.	Did the rearlights operate? [ ] yes [ ] no Fault(s) found:
3.	Did the Interior lights operate normaly? [ ] yes [ ] no Fault(s) found:
4.	Did the head lights operate normaly? [ ] yes [ ] no] Fault(s) found:
5.	Did the water supply of front wipers operate? [ ] yes [ ] no Fault(s) found:
6.
7.
8.
9.

KEMBALI

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Description	Specification	Actual	Serviceable	Unserviceable
No. 1 Piston Outer Diameter