kskv cooling and lubrication system maintenance

8/16/2019 KSKV Cooling and Lubrication System Maintenance

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MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULLUM

COURSE INFORMATION

COURSE NAME

CODE NAME

:

:

COOLING AND LUBRICATION SYSTEM MAINTENANCE

GMA 103

LEVEL : 1 SEMESTER 1

CREDIT UNIT : 3.0

CONTACT HOUR : FACE TO FACE : 6.0 HOURS/WEEK (1T!"#

NON FACE TO FACE :

COURSE TY"E : VOCATIONAL

"RE$RE%UISITE : $

CORE RE%UISITE : $

Module Page 1/51 Document Page 1


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COURSE OUTCOMES

At the end of the course, the students should be able to:-

• R&')*& +&-+)+ 2+

• R&')*& 4)+&- ''

• S&-5*& -))+- )&78

• C)--8 + *29 8+& 29 4-;

• S&-5*& *&- 2+

• R&')*& '-&-& 2+

• C)--8 + &292& 9-&)29

• Replace engine oil pump

COURSE ESCR!"T!O#

T 2+ &2+


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flushing works service manual RPM meter and log book and so that flushing works service manual obtained, thermostat unit removed, flushing

works executed, thermostat unit install, engine performance tested run in accordance with manufacturer’s specification

This unit identifies the competence required to !ervice oil cooler unit using hand tools set, oil cooler service manual, solvent, pressure tester,

torque wrench, gasket, RPM Meter and log book so that oil cooler service manual obtained, oil cooler removed, flushing works executed, oilcooler installed and engine performance tested run in accordance with manufacturer’s specification

This unit identifies the competence required to replace oil pressure unit using hand tools set, new oil pressure unit, white tape and pressure unit

service manual so that pressure unit service manual obtained, external attachments and oil pressure unit removed, oil pressure unit checked, oil

pressure unit installed and oil pressure system tested in accordance with manufacturer’s specification

This unit identifies the competence required to carry out engine greasing using hand tools set, grease gun, grease and machines service manual so

that machines service manual obtained, machine parts greased and service checklist recorded in accordance with manufacturer’s specifications

This unit identifies the competence required to replace engine oil pump using hand tools set, torque wrench, straight edge, machines service

manual, gasket and oil pump repair kit so that machines service manual obtained, lubrication oil drained, oil sump and oil pump assembly

removed, oil pump assembly cleaned, oil pump assembly and oil sump installed and oil pressure tested in accordance with manufacturer’sspecification



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CO#TE#T A# $EAR#!#% STA#ARS

"ROGRAM : AGRICULTURAL MECHANIATION

COURSE NAME : COOLING AND LUBRICATION SYSTEM MAINTENANCE

CODE NAME : GMA 103

COM"ETENCY : 1

CONTENT STANDARD LEARNING STANDARD "ERFORMANCE CRITERIA

1. RE"LACE THERMOSTATUNIT

1.1 O7+)2 *29 8+&&-5*& )2)

""" #dentify sources of cooling system service manual

based on manufacturer’s service manual

""$ %etermine procedures of acquiring cooling system

service manual based on manufacturer’s service

manual

""& %etermine cooling system service manual accordance

with manufacturer’s service manual

""' %etermine source of cooling system service manual

according to manufacturer standard form

""( )cquire cooling system service manual according tomanufacturer standard form

""* #nterpret cooling system service manual according to

manufacturer standard form



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1. D-)2 &292& *)2+ "$" %etermine types of engine cooling system according to


"$$ +xplain functions of engine coolant according to


"$& +xplain functions of radiator cap according to


"$' +xplain procedures of draining engine coolant

accordance with manufacturer’s service manual

"$( %etermine type of engine cooling system #n


"$* %etermine function of engine coolant #n accordance


"$ +xplain open radiator cap accordance with

manufacturer’s service manual

"$- +xplain unscrew draining cork accordance withmanufacturer’s service manual

"$. Perform always loosen the radiator cap very slowly

before removing it to allow pressure in the system



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1.3 R&5& +&-+)+ 2+ "&" #dentify types of radiator hose according to

manufacturer’s standard form

"&$ Removing thermostat housing accordance with


"&& +xplain basic operation of thermostat unit according to

manufacturer’s standard form

"&' Taking out thermostat unit accordance with


"&( %etermine types of radiator hose accordance with


"&* /ninstall radiator hose from thermostat housing


"& %isassemble radiator housing accordance with


"&- Take out thermostat unit accordance with




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1. I2+) +&-+)+ 2+ 11.3

&" %escribe function of thermostat unit accordance withmanufacturer’s service manual

&$ Reassembling radiator housing procedure accordance


&& +xplain techniques of fixing radiator hose accordance


&' Plug thermostat unit accordance with manufacturer’s

service manual

&( Reassemble radiator housing accordance with


&* 0ix radiator hose to thermostat housing accordance


& +nsure thermostat is placing at the right side


1.! R&


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"(& +xplain functions of radiator cap accordance with


"(' %escribe procedures of draining engine coolant


"(( %etermine types of engine coolant accordance with


"(* )ssemble screw draining cork accordance with


"( 1lose radiator cap accordance with manufacturer’s

service manual

"(- Top up engine coolant accordance with manufacturer’s

service manual

1.6 E@&*+& +&+ *29 8+&'&->-)2*&

(" +xplain procedures of engine starting accordance with


($ +xplain procedures of leakage inspection accordancewith manufacturer’s service manual

(& #dentify engine working temperature accordance with




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(' #dentify updating log book accordance with


(( +xplain engine starting procedure accordance withmanufacturer’s service manual

(* +xplain inspect engine leakage accordance with


( 1ompare engine temperature with service manualaccordance with manufacturer’s service manual

(- #nterpret update log book accordance with




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CODE NAME : GMA 103

COM"ETENCY :


. RE"LACE WATER "UM" $" #dentify cooling system service

manual

$"" +xplain sources of cooling system service manual


$"$ +xplain procedures of acquiring cooling system

service manual accordance with manufacturer’s

service manual

$"& #dentify cooling system service manual accordance


$"' %etermine source of cooling system service manual


$"( )cquire cooling system service manual accordance


$"* #nterpret cooling system service manual accordance



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$$ %rain engine coolant $$" #dentify types of engine coolant accordance with


$$$ +xplain functions of engine coolant accordance with


$$& +xplain functions of radiator cap accordance with


$$' %escribe procedures of draining engine coolant


$$( %etermine types of engine coolant accordance with


$$* %etermine function of engine coolant accordance with


$$ 2pen radiator cap accordance with manufacturer’s

service manual

$$- /nscrew draining cork accordance withmanufacturer’s service manual

$$. )pply procedure of draining engine coolant




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$&"3 )pply procedure of removing fan assembly


$&"" #dentify use proper protection personal equipment4PP+5 accordance with manufacturer’s service manual

$' 2btain remove water pump

assembly

.1.1 I&2+>8 +8'& > 4)+&- '' )**-29 + +&+ > + )2 &='&2+.

$'" 6ist function of water pump accordance with


$'$ +xplain procedures of removing water pump


$'& +xplain methods of loosening water pump bolts


$"" %etermine types of water pump according to

manufacturer’s specification

$'' 6oosen water pump bolts accordance with


$'( 0ollow technique of uninstalling water pump unit


$'* )pply procedure of removing water pump accordance




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$( #nstall fan assembly $(" #dentify types of water pump gasket accordance with


$($ %escribe function of water pump gasket accordance


$(& Reinstall new water pump unit accordance with


$(' +xplain techniques of tightening water pump bolt


$(( )ssemble new water pump gasket accordance with


$(* Method of reinstalling new water pump unit


$( 0ollow technique of tightening water pump bolt


$(- #nstall 7ew 8ater Pump )ssembly accordance withmanufacturer’s service manual

$(. /se proper PP+ accordance with manufacturer’s

service manual



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$* Refill engine coolant $*" #dentify types of fan belt according to the list of toolsand equipment

$*$ +xplain procedures of installing fan assembly

according to the maintenance manual

$*& %escribe methods of setting fan belt tension according

to the maintenance manual

$*' %escribe measuring fan belt tension according to the

maintenance manual

$*( Reinstall fan assembly unit according to the

maintenance manual

$** Reinstall fan cover and belt according to themaintenance manual

$* Measure fan belt tension according to the maintenance

manual

$*- )pply procedure of installing fan assembly according

to the maintenance manual

$ Test cooling system performance $" #dentify types of engine coolant accordance with


$$ +xplain functions of engine coolant accordance withmanufacturer’s service manual

$& +xplain functions of radiator cap accordance with




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CODE NAME : GMA 103

COM"ETENCY : 3


3. SERVICE RADIATORASSEMBLY

&" 2btain cooling system service

manual

&"" +xplain source of cooling system service manual


&"$ #dentify procedures of acquiring cooling system

service manual accordance with manufacturer’s

service manual

&"& +xplain cooling system service manual accordancewith manufacturer’s service manual

&"' %etermine source of cooling system service manual


&"( )cquire cooling system service manual accordancewith manufacturer’s service manual



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&"* #nterpret cooling system service manual accordance


&$ %rain engine coolant """ #dentify types of engine coolant according to

manufacturer specification

&$" +xplain functions of engine coolant according to


&$$ +xplain functions of radiator cap according to


&$& %escribe procedures of draining engine coolant

according to manufacturer specification

&$' %etermine types of engine coolant according to


&$( %etermine function of engine coolant according to


&$* 2pen radiator cap according to manufacturer

specification

&$ /nscrew draining cork according to manufacturer

specification

&$- )lways loosen the radiator cap very slowly before

removing it to allow pressure in the system according



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to manufacturer specification

&& Remove radiator unit &&" +xplain functions of radiator unit according tomanufacturer specification

&&$ %isconnecting upper and lower water hose technique


&&& %escribe procedures of removing radiator unit


&&' %etermine function of radiator unit according to


&&( %isconnect upper and lower water hose according to


&&* /ninstall radiator unit from engine according to


&& )pply procedure of removing radiator according to


&' +xecute radiator servicing works &'" #dentify types of radiator defects according to


&'$ %escribe pressuring test procedure according to



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&'& +xplain soldering radiator core, upper and lower tank

procedure according to manufacturer specification

&'' +xplain cleaning radiator fin technique according to


&'( %etermine types of radiator defects according to


&'* )pply pressuring test procedure according to


&' !older radiator core, upper and lower tank accordingto manufacturer specification

&'- 9low radiator fin with pressure air according to


&'. 9rush hard body with detergent according to


&'"3 )pply cleaning radiator fin technique according to


&'"" Meticulous when working with hot components




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&( #nstall radiator unit &(" +xplain function of radiator unit according to


&($ %escribe procedures of installing radiator unit


&(& #dentify techniques of connecting upper and lower

water hose according to manufacturer specification

&(' %escribe methods of reinstall radiator unit to engine


&(( %etermine function of radiator unit according to


&(* Methods of reinstall radiator unit to engine according


&( Reconnect upper and lower water hose according to


&(- 0ollow procedure of installing radiator according to


&* Refill engine coolant &*" #dentify types of engine coolant according to




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&*$ %escribe functions of engine coolant according to


&*& %escribe functions of radiator cap according tomanufacturer specification

&*' +xplain draining engine coolant procedure according


&*( %etermine types of engine coolant according tomanufacturer specification

&** !crew draining cork according to manufacturer

specification

&* 1lose radiator cap according to manufacturer

specification

&*- Top up engine coolant according to manufacturer

specification

&*. )void splash coolant to floor according tomanufacturer specification

& Test cooling system performance '" +xplain engine starting procedure according to


'$ %escribe leakage inspect procedure according to




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'& %efine engine working temperature according to


'' !tate techniques of testing cooling system

performance according to manufacturer specification

'( /pdating log book according to manufacturer

specification

'* )pply engine starting procedure according to


' #nspect engine leakage according to manufacturer

specification

'- 1ompare engine temperature with service manual


'. 0ollow technique of testing cooling system

performance according to manufacturer specification

'"3 /pdate log book according to manufacturer

specification



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CODE NAME : GMA 103

COM"ETENCY :


. CARRY OUT COOLINGSYSTEM FLUSHING WORKS

'" 2btain flushing works service

manual

'"" #dentify sources of flushing works service manual


'"$ %escribe procedures of acquiring flushing works

service manual according to manufacturer

specification

'"& #dentify flushing works service manual according tomanufacturer specification

'"' %etermine source of flushing works service manual


'"( )cquire flushing works service manual according to


'"* #nterpret flushing works service manual according to




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'$ Remove thermostat unit '$" #dentify types of radiator hose according tomanufacturer specification

'$$ +xplain methods of removing thermostat housing


'$& %escribe basic operation of thermostat unit according


'$' !tate taking out thermostat unit according tomanufacturer specification

'$( %etermine types of radiator hose according to


'$* /ninstall radiator hose from thermostat housing


'$ %isassemble radiator housing according to


'$- Take out thermostat unit according to manufacturerspecification

'$. )lways loosen the radiator cap very slowly before

removing it to allow pressure in the system according



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'& +xecute flushing works '&" +xplain purpose of flushing works according tomanufacturer specification

'&$ !tate types of flushing machine according to


'&& %escribe procedures of flushing works according to


'&' %etermine purpose of flushing works according tomanufacturer specification

'&( 0ix flushing machine to cooling system according to


'&* )pply procedure of flushing works according to


'& Meticulous when using flushing chemical according to


'' #nstall thermostat unit ''" +xplain function of thermostat unit according to


''$ +xplain procedures of reassembling radiator housing



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''& %escribe techniques of fixing radiator hose according


''' Plug thermostat unit according to manufacturer

specification

''( Reassemble radiator housing according to


''* 0ix radiator hose to thermostat housing according to


'' +nsure thermostat is placing at the right side accordingto manufacturer specification

'( Test run engine performance '(" +xplain procedures of engine starting according to


'($ +xplain procedures of leakage inspection according to


'(& %efine engine working temperature according to




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'(' %escribe methods of testing engine performance


'(( /pdating log book according to manufacturerspecification

'(* 1hecking engine leakage according to manufacturer

specification

'( )pply procedure engine starting according tomanufacturer specification

'(- #nspect engine leakage according to manufacturer

specification

'(. 1ompare engine temperature with service manual


'("3 Tune engine idling revolution per minute4RPM5


'("" )pply method of testing engine performanceaccording to manufacturer specification

'("$ /pdate log book according to manufacturer

specification



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CODE NAME : GMA 103

COM"ETENCY : !

CONTENTSTANDARD

LEARNING STANDARD "ERFORMANCE CRITERIA

!. SERVICE OILCOOLER UNIT

(" 2btain oil cooler service manual ("" #dentify source of oil cooler service manual according to


("$ %escribe procedures of acquiring oil cooler service manualaccording to manufacturer specification

("& !tate oil cooler service manual according to manufacturer

specification

("' %etermine source of oil cooler service manual according to


("( )cquire oil cooler service manual according to manufacturer

specification

("* #nterpret oil cooler service manual according to manufacturer

specification

(" 1arefully read and observe precaution warnings given by



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CONTENTSTANDARD


manual according to manufacturer specification

($ Remove oil cooler ($" +xplain operation of oil cooler according to manufacturer

specification

($$ +xplain function of oil cooler according to manufacturer

specification

($& %escribe procedures of removing oil cooler according to


($' %etermine operation of oil cooler according to manufacturer

specification

($( %etermine function of oil cooler according to manufacturer

specification

($* /ninstall oil cooler from engine according to manufacturer

specification

(& +xecute flushing works (&" #dentify types of flushing fluid according to manufacturer

specification

(&$ #dentify types of oil cooler defects according to manufacturer

specification



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CONTENTSTANDARD


(&& %escribe procedures of flushing oil cooler according to


(&' #dentify oil cooler pressure test according to manufacturer

specification

(&( %etermine types of flushing fluid according to manufacturer

specification

(&* %etermine types of oil cooler defects according to


(& 0ollow procedure of flushing oil cooler according to


(&- )pply method of oil cooler pressure test according to


(&. Meticulous when using flushing chemical according to


(' #nstall oil cooler ('" #dentify operation of oil cooler according to manufacturer

specification

('$ +xplain function of oil cooler according to manufacturer

specification

('& %escribe procedures of installing oil cooler according to



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CONTENTSTANDARD



('' %etermine operation of oil cooler according to manufacturer

specification

('( %etermine function of oil cooler according to manufacturer

specification

('* 0ollow procedure of reinstalling oil cooler to engine


(' Meticulous when working with hot components according to


(( Test run engine performance ((" +xplain engine starting procedure according to manufacturer

specification

(($ %escribe leakage inspect procedure according to


((& #dentify engine working temperature according tomanufacturer specification

((' %escribe methods of testing engine performance according tomanufacturer specification

((( /pdating log book according to manufacturer specification



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CONTENTSTANDARD


((* )pply engine starting procedure according to manufacturer

specification

(( #nspect engine leakage according to manufacturer

specification

((- 1ompare engine temperature with service manual according


((. )pply testing engine performance method according to


(("3 /pdate log book according to manufacturer specification



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*$ Remove external attachments *$" #dentify type of battery terminal according to


*$$ #dentify types of electrical cable according to


*$& %efine oil pressure electrical circuit according to


*$' #dentify types of lubrication oil pipes according to


*$( +xplain methods of removing external attachments


*$* %isconnect battery terminal according to manufacturer

specification

*$ %etermine types of electrical cable according to


*$- %etermine oil pressure electrical circuit according to


*$. %etermine types of lubrication oil pipes according to


*$"3 %isconnect electrical and piping connection according




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*$"" %isconnect negative battery terminal first according to


*& 1heck oil pressure unit *&" +xplain function of oil pressure unit according tomanufacturer specification

*&$ #dentify types of oil pressure unit defects according to


*&& +xplain procedures of checking oil pressure unit defect


*&' %etermine function of oil pressure unit according tomanufacturer specification

*&( %etermine types of oil pressure unit defects accordingto manufacturer specification

*&* )pply procedure of checking oil pressure unit defect


*' 2btain install oil pressure unit *'" #dentify types of oil pressure unit according to


*'$ %escribe operation of oil pressure unit according to




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*'& +xplain methods of installing oil pressure unit to

engine according to manufacturer specification

*'' %etermine types of oil pressure unit according tomanufacturer specification

*'( %etermine operation of oil pressure unit according to


*'* )pply method of reinstalling oil pressure unit toengine according to manufacturer specification



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CODE NAME : GMA 103

COM"ETENCY :


. CARRY OUT ENGINEGREASING

.1 O7+)2 )*2& &-5*&)2)

"" #dentify source of machines service manual according


"$ +xplain procedures of acquiring machines service

manual according to manufacturer specification

"& #dentify types of machines service manual according


"' %etermine source of machines service manual


"( )cquire machines service manual according to


"* #nterpret machines service manual according to




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$- 1hange of defective nipples according to manufacturer

specification

$. )pply greasing procedure according to manufacturer

specification

$"3 /se grease gun to in:ect grease in grease nipple


.3 R&*- &-5*& *&*;+ &" #dentify types of service checklist according to


&$ !tate technique of fill in service checklist according tomanufacturer specification

&& +xplain methods of fill in service checklist accordingto manufacturer specification

&' Recording of service checklist according to


&( 0iling of service checklist according to manufacturer

specification

&* %etermine types of service checklist according to


& 0ill in service checklist according to manufacturer



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CODE NAME : GMA 103

COM"ETENCY :

CONTENTSTANDARD


. R&')*& &292& ''

-" 2btain machines service manual -"" +xplain source of machines service manual according to


-"$ +xplain procedures of acquiring machines service manualaccording to manufacturer specification

-"& #dentify types of machines service manual according to


-"' %etermine source of machines service manual according to


-"( )cquire machines service manual according to manufacturer

specification

-"* #nterpret machines service manual according to manufacturer

specification



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CONTENTSTANDARD


-$ %rain lubrication oil -$" #dentify types of lubrication oil according to manufacturer

specification

-$$ !tate function of lubrication oil according to manufacturer

specification

-$& +xplain lubricating system according to manufacturer

specification

-$' %etermine typ

es of lubrication oil according to manufacturer specification

-$( %etermine function of lubrication oil according to


-$* %etermine lubricating system according to manufacturer

specification

-$ /nplug lubrication oil drain plug according to manufacturer

specification

-$- %ispose used lubrication oil according to %epartment of

+nvironmental rules and regulation

-& Remove oil sump -&" #dentify types of sump gasket according to manufacturer

specification

-&$ +xplain function of oil sump according to manufacturer



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CONTENTSTANDARD


specification

-&& %escribe procedures of removing oil sump according to


-&' %etermine types of sump gasket according to manufacturer

specification

-&( %etermine function of oil sump according to manufacturer

specification

-&* Take out oil sump according to manufacturer specification

-' 1lean oil pump assembly -'" #dentify type of oil pump according to manufacturer

specification

-'$ +xplain function of oil pump according to manufacturer

specification

-'& %escribe operation of oil pump according to manufacturer

specification

-'' 6ist cleaning oil pump assembly method according to


-'( %etermine type of oil pump according to manufacturer

specification



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CONTENTSTANDARD


-'* %etermine function of oil pump according to manufacturer

specification

-' %etermine operation of oil pump according to manufacturerspecification

-'- )pply cleaning oil pump assembly method according to


-( #nstall oil pump assembly -(" #dentify type of oil pump according to manufacturer

specification

-($ +xplain function of oil pump according to manufacturer

specification

-(& %escribe operation of oil pump according to manufacturer

specification

-(' %escribe methods of installing oil pump assembly according


-(( %etermine types of oil pump according to manufacturer

specification

-(* %etermine function of oil pump according to manufacturerspecification

-( %etermine operation of oil pump according to manufacturer

specification



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CONTENTSTANDARD


-(- Reassemble oil pump assembly to location according to


-* #nstall oil sump assembly -*" #dentify types of sump gasket according to manufacturer

specification

-*$ %escribe function of oil sump according to manufacturer

specification

-*& +xplain procedures of removing oil sump according to


-*' %escribe methods of installing oil sump according to


#-*( Place sump gasket according to manufacturer specification

-** #nspect oil sump surface from distortion according to


-* 0ix oil sump to engine block according to manufacturer

specification

-*- )pply method of installing oil sump according to




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CONTENTSTANDARD


- Test oil pressure -" +xplain engine starting procedure according to manufacturer

specification

-$ !tate leakage inspection procedure according to manufacturer

specification

-& #dentify engine working temperature according to


-' %escribe methods of testing oil pressure according to


-( /pdating log book according to manufacturer specification

-* )pply engine starting procedure according to manufacturer

specification

- 1heck engine leakage according to manufacturer

specification

-- 1heck oil pressure gauge according to manufacturerspecification

-. )pply testing oil pressure method according to manufacturer

specification

-"3 /pdate log book according to manufacturer specification

-"" Meticulous when filling service checklist form according to



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CONTENTSTANDARD




kskv cooling and lubrication system maintenance

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