5452 Demonstrate Knowledge of Cummins Diesel Fuel Injectors, and Overhaul Them

Explanatory notes

1The following legislation and amendments are required to be consulted and followed where applicable:

Health and Safety in Employment Act, 1992.

2Reference to suitable tools and workshop equipment means industry approved tools and equipment that are recognised within the industry as being the most suited to complete the task to a professional and competent manner with due regard to safe working practices.

Outcomes and evidence requirements

Outcome 1

Demonstrate knowledge of Cummins PT and PT Top Stop type fuel injectors.

Evidence requirements

1.1Injector construction is described according to manufacturer’s manual description.

Rangenames of parts, shapes of parts, locations of parts.

1.2Injector nozzle operation is explained according to manufacturer’s manual explanation.

Rangefuel pressure path, needle valve operation, spray patterns.

1.3The importance of cleanliness when working with fuel injectors is identified.

Rangecontamination, precise machining tolerances and close operating fits of parts, damage, premature failure.

1.4Faults which affect injector operation are described according to manufacturer’s manual fault finding chart.

Rangefuel contamination, wear, opening pressure, leakage, damage.

1.5Removing and refitting procedures are described according to manufacturer’s manual instructions.

Rangesealing, cleanliness of injector and surrounding area, torque settings.

1.6Overhaul procedures are described according to manufacturer’s manual instructions.

Rangecleaning, testing, dismantling, rectifying faults, reassembling.

Outcome 2

Overhaul Cummins diesel fuel injectors.

Evidence requirements

2.1Safe working practices are observed throughout the task.

Rangepersonal safety, safety of others, equipment safety, safety precautions when working with high pressure fuel.

2.2Suitable tools and workshop equipment are selected and used, to enable the injectors to be overhauled according to manufacturer's specifications.

2.3The injectors are mounted and dismantled on a stripping jig according to manufacturer's instructions.

2.4All parts are cleaned to enable an inspection to be carried out.

2.5A condition report is completed and given to the supervisor.

Rangeinspection of parts, identifying and recording faults, recommending repairs and replacement of parts.

2.6All parts that are determined as needing replacement are ordered from a supplier.

Rangeinterpreting parts catalogues, using up-dates and supersessions, obtaining pricing and delivery details.

2.7The injectors are reassembled according to manufacturer's instructions and specifications.

2.8The injectors are mounted and set up for calibration on a test rig according to manufacturer's instructions.

2.9The injectors are calibrated according to manufacturer's specifications.

2.10The injectors are removed from the test bench with fuel inlets, fuel outlets, and adjustments sealed.

This unit standard is expiring. Assessment against the standard must take place by the last date for assessment set out below.

Status information and last date for assessment for superseded versions

This CMR can be accessed at

Please note

Providers must be granted consent to assess against standards (accredited) by NZQA, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.

Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.

Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.

Requirements for consent to assess and an outline of the moderation system that applies to this standard are outlined in the Consent and Moderation Requirements (CMR). The CMR also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.