Engine Compartment Inspection - CareerTech (CT) · MAVCC—Diesel Technology: Preventive Maintenance Page 119 Job Sheet 1—Inspect and Adjust Alternator Drive Belts and Tensioners

MAVCC—Diesel Technology: Preventive Maintenance Page 119

Job Sheet 1—Inspect and Adjust Alternator Drive Belts and Tensioners

Name ________________________________ Attempt Number ________

Date _________________________________ Overall Rating ________

Evaluation Criteria Rating

• Directionsarefollowed _______• Safetyproceduresarefollowed _______• Servicemanualisusedproperly _______• Proceduresarefollowedaccurately _______• Jobticketisfilledoutproperly _______• Cleanupisadequate _______

Basic Skills

Reading Critical

Thinking Employability

Introduction To check for a loose belt, press on the center of the belt with your thumb, or use a belt tension gauge. When testing with your thumb, the belt should flex about one-half inch. Refer to the tension gauge manufacturer’s instructions for specifications. When inspecting the belt for looseness also check for deterioration, cracks, grease or oil contamination, and glazing. If the belt is damaged, replace it. If the belt is loose, tighten it only enough to prevent the belt from slipping or flapping. If the belt is tightened too much, it may cause damage to the alternator.

Instructions When you are ready to perform this task, ask your instructor to observe the procedure and rate your performance using the evaluation criteria.

Tools, Equipment, and Materials

• Vise • Replacementalternatordrivebelts,pulleys,andfans • Technician’scommonhandtools • Appropriateservicemanual • Jobticket—oneisincludedoruseappropriateoneprovidedatyourfacility • Wheelchocks • Belttensiongauge • Safetyglasses • Otherequipmentandsuppliesasrequiredbyprocedure

Procedure ❏ 1. Locate and follow the appropriate procedure in the service manual.

❏ 2. Complete the accompanying job ticket with all pertinent information.

Engine Compartment Inspection

Page 120 MAVCC—Diesel Technology: Preventive Maintenance

❏ 3. Using a belt tension gauge and specifications from the appropriate service manual, determine belt tension on both the alternator and drive belts.

Belt tension adjustment procedures

❏ 1. Loosen the adjustor bolt and/or tensioner (if so equipped).

✔ Note: Vehicles equipped with serpentine belts do not have adjuster belts.

❏ a. Loosen the belt by moving the alternator or the tensioner in toward the engine.

❏ b. Tighten the belt by moving the alternator or the tensioner away from the engine.

❏ 2. Re-check belt tension on the belt tightened or loosened.

❏ 3. Have your instructor check your work.

❏ 4. Turn in job ticket when finished.

❏ 5. Clean work area and return tools and materials to proper storage.

Evaluator’s Comments: __________________________________________

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Job Sheet 1


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Job Sheet 1


Job Sheet 2—Take Oil Sample, and Change Oil and Filter(s)




• Correctproceduresareidentifiedforassignedvehicle _______• Proceduresarecompletedcorrectly _______• Propertoolsareusedcorrectly _______• Safetyprecautionsareobserved _______• Installedequipmentfunctionscorrectly _______• Servicedequipmentmeetsspecifications _______• Clean-upandfollow-upactionsareadequate _______

Basic Skills

Reading Critical




• Technician’scommonhandtools • Appropriateengineservicemanual • Jobticketorworkorder—oneisincludedoruseappropriateoneprovidedat

your facility • Safetyglasses • Replacementfilter(s) • Correcttypeandamountofreplacementoil • Funneland/orspout • Containertocatchwasteoil • Oilfilterwrench • Otherequipmentandsuppliesasrequiredbyprocedure

Guidelines 1. Make sure that all funnels and spouts are clean.

2. Prelube replacement filters by filling them with clean oil before installation.

3. Dispose of waste oil and filter elements in accordance with EPA guidelines.

4. Place all oily shop towels in approved airtight storage containers.





❏ 3. Thoroughly clean the area around the engine drain plug and oil filter housing.

❏ 4. Visually inspect the engine for signs of oil leakage. Note these on the job ticket.

❏ 5. After performing the sampling procedure, be sure that the label is accurately filled out and attached to the sample bottle.

❏ 6. After removing filter/filter element, wipe all mating surface carefully with a clean shop towel.

❏ 7. Lightly oil O-rings or filter base gaskets before installing. Closely follow the filter manufacturer’s tightening recommendations.

❏ 8. Add oil or refill crankcase as required.

❏ 9. Start the engine and watch carefully for oil pressure. If there is no oil pressure indication within 15 seconds of startup, shut the engine down and find out why.

❏ 10. Allow the engine to run for several minutes; check for leaks.

❏ 11. Shut down the engine. Wait a minute, then check the oil level. Add oil if necessary.





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Job Sheet 2


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Job Sheet 2


Job Sheet 3—Inspect Engine Coolant Level and Condition





Basic Skills

Reading Critical





your facility • Recommendedcoolantservicekitforassignedcoolingsystem • Flashlight • Safetyglasses • Otherequipmentandsuppliesasrequiredbyprocedure

Guidelines 1. Ensure that engine is stopped before beginning this procedure.

2. Relieve system pressure before removing radiator cap.

3. Clean up any spilled antifreeze solution—it makes metal and concrete surfaces very slippery.



❏ 3. Remove the radiator cap and withdraw a suitable amount of coolant.



❏ 4. Use kit as directed to check for appropriate levels of coolant levels. Be sure to check nitrate level, pH, and freezing point, as well as any others recommended. Record findings on job ticket.

❏ 5. Compare levels with manufacturer's recommendations. Record on job ticket.

❏ 6. Add supplemental coolant additives as directed. Record on job ticket.

❏ 7. If coolant level is low, add approved coolant to the system until level is correct.

❏ 8. Service coolant filter according to the service manual.





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Job Sheet 3


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Job Sheet 3


Job Sheet 4—Pressure Test Coolant System and Radiator Cap





Basic Skills

Reading Critical





your facility • Safetyglasses • Radiatorpressuretesterwithcapadapter • Otherequipmentandsuppliesasrequiredbyprocedure

Guidelines 1. Ensure that engine is stopped before beginning this procedure.

2. Relieve system pressure before removing radiator cap.

3. Clean up any spilled antifreeze solution—it makes metal and concrete surfaces very slippery.

Procedures ❏ 1. Locate and follow the appropriate procedure in the service manual.


❏ 3. Remove the radiator cap. Make sure the coolant level is correct and that the radiator filler neck is clean and free of burrs or dents.



❏ 4. Install the tester in the filler neck, being sure to seat it squarely and completely.

❏ 5. Pressurize the system with the hand pump while watching the gauge on the tester.

✔ Note: Do not exceed the manufacturer's recommended pressure. Over-pressurizing the radiator will damage and deform the core and cause seam leaks.

❏ 6. Observe the tester's pressure gauge; it should be holding steady.

❏ 7. Visually inspect all coolant hoses for signs of seepage or swelling.

❏ 8. Slowly release the pressure, and remove the tester from the radiator.

❏ 9. Using the cap adapter, connect the radiator cap to the tester.

❏ 10. Repeat steps #5 and #6.

❏ 11. Release the pressure. If the cap checks good, reinstall it; if bad, replace it.





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Job Sheet 4


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Job Sheet 4


Job Sheet 5—Make a Charging System Output Test; Determine Needed Repairs




• Directionsarefollowed _______• Safetyproceduresarefollowed _______• Servicemanualisusedproperly _______• Proceduresarefollowedaccurately _______• Jobticketisfilledoutproperly _______• Cleanupisadequate _______

Basic Skills

Reading

3

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Mathematics

CriticalThinking

Employability

Introduction A charging system output test measures the maximum current the alternator can produce at a specified voltage or maximum load. A charging system output test should be done when low generator voltage and current is suspected. A load tester, VAT tester, or ammeter may be used to measure the current. Procedures differ with non-inductive testers. Always check the operating directions of the tester before connecting to charging components. When using an ammeter to perform an output test, calculate the charging system output by adding the two ammeter readings together and compare these figures with the manufacturer’s specifications to determine needed tests and repairs. For instance, if the system tests low, a regulator voltage and regulator bypass test is usually required to determine if the alternator, regulator, or circuit wiring is at fault.

Some guidelines to prevent damage to the charging and other electrical systems when working with charging system components are:

• Disconnectthebatterybeforeremovinganychargingsystemcomponent.

• Neverreversepolaritywhenconnectingjumpercablestothebattery.

• Donot operate the alternator with the output disconnected.

• Nevershortorgroundanychargingsystemterminal.



The output of the generator is sized or rated to meet the demands of the vehicle. For example, a vehicle with many accessories will have a higher amp size rating than a vehicle with a few accessories. Always check the size or rating of the alternator being tested in the appropriate service manual.



• Loadtester/ammeter/inductiveampgauge • Technician’scommonhandtools • Appropriateservicemanual • Jobticket—oneisincludedoruseappropriateoneprovidedatyourfacility • Safetyglasses • Otherequipmentandsuppliesasrequiredbyprocedure

✔ Note: Procedures vary with the vehicle. Always check the procedure in the service manual before beginning any service or repair.







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Job Sheet 5


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Job Sheet 5


Job Sheet 6—Perform an Engine Compartment Inspection




• Checklistisfollowed _______• Discrepanciesaredocumented _______• Directionsarefollowed _______• Safetyproceduresarefollowed _______• Jobticketisfilledoutproperly _______• Cleanupisadequate _______

Basic Skills

Reading Critical


Introduction Use the attached checklist to perform your inspection. Remember that items should be checked in a normal flow pattern.



• Technician’scommonhandtools • Appropriateservicemanual • Jobticket—oneisincludedoruseappropriateoneprovidedatyourfacility • Safetyglasses • Shoptowels • Otherequipmentandsuppliesasrequiredbyinspection

Procedure ✔ Note: The procedure for performing this inspection may vary due to the type of vehicle and type of equipment installed on the vehicle.


❏ 2. Use the provided abbreviated checklist to complete the inspection.

❏ 3. Document all discrepancies on the job ticket.






Inspection Code: -OK o–Followup Needed x-Adjusted, Serviced/Repaired NA–Not Applicable


Unit Number Odometer Reading Customer Name Repeat Order Number

Reefer Due? List Campaigns Due Location Name Location Code Date

Inspection Item Code Init.Engine OffCheck belts, tensioners, and pulleys; check and adjust belt tension; checkbelt alignmentCheck engine oil level and condition; check dipstick sealTake an engine oil sampleCheck engine for oil, coolant, air, and fuel exhaust leaksChange engine oil and filters; visually check oil for coolant or fuelcontamination; inspect and clean magnetic drain plugsCheck engine compartment wiring harnesses, connectors, and seals fordamage and proper routingCheck starter, mounting, and connectionsCheck alternator, mountings, wiring and wiring routingCheck windshield washer fluid level; fill as necessaryCheck master cylinder fluid level and conditionCheck hydraulic clutch slave and master cylinders, lines, fittings,and hoses, if applicableCheck brake assist system (booster), hoses, and control valves; checkreservoir fluid level and conditionCheck power steering fluid and filterCheck power steering pump, mounting, and hoses for leaks, condition,and routing; check fluid levelCheck steering gear for leaks and secure mountingCheck steering shaft U-joints, pinch bolts, splines, Pitman arm-to-steeringsector shaft, tie rod ends, and linkagesCheck A/C condenser and lines for condition and visible leaks;check mountingsCheck A/C compressor and lines for condition and visible leaks;check mountingsCheck fuel pump and fuel line mountingsCheck water separator/fuel heater; replace fuel filter(s); prime and bleedfuel systemService or replace air filter as needed; check and reset air filter restrictionindicatorCheck turbocharger for leaks; check mountings and connectionsCheck radiator (including air flow restriction, leaks, and damage)and mountings

Job Sheet 6


Inspection Code: -OK o–Followup Needed x-Adjusted, Serviced/Repaired NA–Not Applicable


Unit Number Odometer Reading Customer Name Repeat Order Number

Reefer Due? List Campaigns Due Location Name Location Code Date

Inspection Item Code Init.Service coolant filterCheck coolant recovery systemCheck coolant hoses and clampsCheck coolant for contamination, additive packageconcentration, and protection level (freeze point)Pressure test cooling system and radiator capCheck fan assembly and shroudInspect water pump for leaks and bearing playInspect and service crankshaft ventilation systemEngine OnCheck engine for oil, coolant, air, and fuel and exhaust leaksCheck air induction system; piping, charge air cooler, hoses, clamps, andmounting; check for air restrictions and leaksCheck transmission oil level, type, and condition (automatic transmissions)Check/record alternator current and voltage output (alternator current/voltageoutput tests)Check A/C system condition and operation; check A/C monitoring system,if applicableCheck operation of engine compression/exhaust brakeCheck operation of fan clutchCheck HVAC air inlet filters and ducts; service as needed

Job Sheet 6


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Job Sheet 6

Documents

Engine Compartment Inspection - CareerTech (CT) · MAVCC—Diesel Technology: Preventive Maintenance Page 119 Job Sheet 1—Inspect and Adjust Alternator Drive Belts and Tensioners