DPE 1040 - Preventative Maintenance

Students will:

• Identify and practice general shop safety rules and procedures.
• Utilizing safe procedures for handling of tools and equipment.
• Identifying and using proper placement of floor jacks and jack stands.
• Identifying and using proper procedures for safe lift operation.
• Utilizing proper ventilation procedures for working within the lab/shop area.
• Identifying marked safety areas.
• Identifying the location and the types of fire extinguishers and other fire safety equipment.
• Demonstrating knowledge of the procedures for using fire extinguishers and other fire safety equipment.
• Identifying the location and use of eye wash stations.
• Identifying the location of the posted evacuation routes.
• Complying with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.
• Identifying and wearing appropriate clothing for lab/shop activities.
• Securing hair and removing jewelry for lab/shop activities.
• Demonstrating awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, and hybrid vehicle high voltage circuits.
• Demonstrating awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignition systems, injection systems, etc.).
• Locating and demonstrating knowledge of material safety data sheets (MSDS).

Tools and Equipment

• Identify tools and their usage in automotive applications.
• Identifying standard and metric designation.
• Demonstrating safe handling and use of appropriate tools.
• Demonstrating proper cleaning, storage, and maintenance of tools and equipment.
• Demonstrating proper use of precision measuring tools
• Examples: micrometer, dial-indicator, dial-caliper

Diesel Engine

• Check engine starting/operation (including unusual noises, vibrations, exhaust smoke, etc.); record idle and governed rpm.
• Inspect vibration damper.
• Inspect belts, tensioners, and pulleys; check and adjust belt tension; check belt alignment.
• Check engine oil level and condition; check dipstick seal.
• Inspect engine mounts for looseness and deterioration.
• Check engine for oil, coolant, air, fuel, and exhaust leaks (Engine Off and Running).
• Check engine compartment wiring harnesses, connectors, and seals for damage and proper routing.

Diesel Fuel Systems

• Check fuel tanks, mountings, lines, caps, and vents.
• Drain water from fuel system.
• Service water separator/fuel heater; replace fuel filter(s); prime and bleed fuel system.

Air Induction and Exhaust System

• Check exhaust system mountings for looseness and damage.
• Check engine exhaust system for leaks, proper routing, and damaged or missing components to include exhaust gas recirculation (EGR) system and after treatment devices, if equipped.
• Check air induction system: piping, charge air cooler, hoses, clamps, and mountings; check for air restrictions and leaks.
• Inspect turbocharger for leaks; check mountings and connections.
• Check operation of engine compression/exhaust brake.
• Service or replace air filter as needed; check and reset air filter restriction indicator.
• Inspect and service crankcase ventilation system.
• Inspect diesel exhaust fluid (DEF) system, to include tanks, lines, gauge pump, and filter.
• Inspect selective catalyst reduction (SCR) system; including diesel exhaust fluid (DEF) for proper levels, leaks, mounting and connections.

Cooling System

• Check operation of fan clutch.
• Inspect radiator (including air flow restriction, leaks, and damage) and mountings.
• Inspect fan assembly and shroud.
• Pressure test cooling system and radiator cap.
• Inspect coolant hoses and clamps.
• Inspect coolant recovery system.
• Check coolant for contamination, additive package concentration, aeration, and protection level (freeze point).
• Service coolant filter.
• Inspect water pump.

Lubrication System

• Change engine oil and filters; visually check oil for coolant or fuel contamination; inspect and clean magnetic drain plugs.
• Take an engine oil sample for analysis.

Cab Instruments and Controls

• Inspect key condition and operation of ignition switch.
• Check warning indicators.
• Check instruments; record oil pressure and system voltage.
• Check operation of electronic power take off (PTO) and engine idle speed controls (if applicable).
• Check HVAC controls.
• Check operation of all accessories.
• Using electronic service tool(s) or on-board diagnostic system; retrieve engine monitoring information; check and record diagnostic codes and trip/operational data (including engine, transmission, ABS, and other systems).

Cab and Hood Safety Equipment

• Check operation of electric/air horns and reverse warning devices.
• Check condition of spare fuses, safety triangles, fire extinguisher, and all required decals.
• Inspect seat belts and sleeper restraints.
• Inspect wiper blades and arms.

Cab and Hood Hardware

• Check operation of wiper and washer.
• Inspect windshield glass for cracks or discoloration; check sun visor.
• Check seat condition, operation, and mounting.
• Check door glass and window operation.
• Inspect steps and grab handles.
• Inspect mirrors, mountings, brackets, and glass.
• Record all observed physical damage.
• Lubricate all cab and hood grease fittings.
• Inspect and lubricate door and hood hinges, latches, strikers, lock cylinders, safety latches, linkages, and cables.
• Inspect cab mountings, hinges, latches, linkages and ride height; service as needed.
• HVAC
• Inspect A/C condenser and lines for condition and visible leaks; check mountings.
• Inspect A/C compressor and lines for condition and visible leaks; check mountings.
• Check A/C system condition and operation; check A/C monitoring system, if applicable.
• Check HVAC air inlet filters and ducts; service as needed.

Battery and Starting Systems

• Inspect battery box(es), cover(s), and mountings.
• Inspect battery hold-downs, connections, cables, and cable routing; service as needed.
• Check/record battery state-of-charge (open circuit voltage) and condition.
• Perform battery test (load and/or capacitance).
• Inspect starter, mounting, and connections.
• Engage starter; check for unusual noises, starter drag, and starting difficulty.

Charging System

• Inspect alternator, mountings, cable, wiring, and wiring routing; determine needed action.
• Perform alternator output tests.

Lighting System

• Check operation of interior lights; determine needed action.
• Check all exterior lights, lenses, reflectors, and conspicuity tape; check headlight alignment; determine needed action.
• Inspect and test tractor-to-trailer multi-wire connector(s), cable(s), and holder(s); determine
• needed action.

Air Brakes

• Check operation of parking brake.
• Record air governor cut-in and cut-out setting (psi).
• Check operation of air reservoir/tank drain valves.
• Check air system for leaks (brakes released).
• Check air system for leaks (brakes applied).
• Test one-way and double-check valves.
• Check low air pressure warning devices.
• Check emergency (spring) brake control/modulator valve, if applicable.
• Check tractor protection valve.
• Test air pressure build-up time.
• Inspect coupling air lines, holders, and glad hands.
• Check brake chambers and air lines for secure mounting and damage.
• Check operation of air drier.
• Inspect and record brake shoe/pad condition, thickness, and contamination.
• Inspect and record condition of brake drums/rotors.
• Check antilock brake system wiring, connectors, seals, and harnesses for damage and proper routing.
• Check operation and adjustment of brake automatic slack adjusters (ASA); check and record push rod stroke.
• Lubricate all brake component grease fittings.
• Check condition and operation of hand brake (trailer) control valve, if applicable.
• Perform antilock brake system (ABS) operational system self-test.
• Drain air tanks and check for contamination.
• Check condition of pressure relief (safety) valves.

Hydraulic Brakes

• Check master cylinder fluid level and condition.
• Inspect brake lines, fittings, flexible hoses, and valves for leaks and damage.
• Check parking brake operation; inspect parking brake application and holding devices; adjust as needed.
• Check operation of hydraulic system: pedal travel, pedal effort, pedal feel.
• Inspect calipers for leakage, binding and damage.
• Inspect brake assist system (booster), hoses and control valves; check reservoir fluid level and condition.
• Inspect and record brake lining/pad condition, thickness, and contamination.
• Inspect and record condition of brake rotors.
• Check antilock brake system wiring, connectors, seals, and harnesses for damage and proper routing.

Diesel Drivetrain

• Check operation of clutch, clutch brake, and gearshift.
• Check clutch linkage/cable for looseness or binding, if applicable.
• Check hydraulic clutch slave and master cylinders, lines, fittings, and hoses, if applicable.
• Check clutch adjustment; adjust as needed.
• Check transmission case, seals, filter, hoses, lines and cooler for cracks and leaks.
• Inspect transmission breather.
• Inspect transmission mounts.
• Check transmission oil level, type, and condition.
• Inspect U-joints, yokes, driveshafts, boots/seals, center bearings, and mounting hardware for looseness, damage, and proper phasing.
• Inspect axle housing(s) for cracks and leaks.
• Inspect axle breather(s).
• Lubricate all drive train grease fittings.
• Check drive axle(s) oil level, type, and condition.
• Change drive axle(s) oil and filter/screen, if applicable; check and clean magnetic plugs.
• Check transmission wiring, connectors, seals, and harnesses for damage and proper routing.
• Change transmission oil and filter, if applicable; check and clean magnetic plugs.
• Check interaxle differential lock operation.
• Check transmission range shift operation.

Suspension and Steering Systems

• Check steering wheel operation for free play and binding.
• Check power steering pump, mounting, and hoses for leaks, condition, and routing; check fluid level.
• Change power steering fluid and filter.
• Inspect steering gear for leaks and secure mounting.
• Inspect steering shaft U-joints, pinch bolts, splines, pitman arm-to-steering sector shaft, tie rod ends, and linkages.
• Check kingpins for wear.
• Check wheel bearings for looseness and noise.
• Check oil level and condition in all non-drive hubs; check for leaks.
• Inspect springs, pins, hangers, shackles, spring U-bolts, and insulators.
• Inspect shock absorbers for leaks and secure mounting.
• Inspect air suspension springs, mounts, hoses, valves, linkage, and fittings for leaks and damage.
• Check and record suspension ride height.
• Lubricate all suspension and steering grease fittings.
• Check axle locating components (radius, torque, and/or track rods).

Tires and Wheels

• Inspect tires for wear patterns and proper mounting.
• Inspect tires for cuts, cracks, bulges, and sidewall damage.
• Inspect valve caps and stems; determine needed action.
• Measure and record tread depth; probe for imbedded debris.
• Check and record air pressure; adjust air pressure in accordance with manufacturers’ specifications.
• Check wheel mounting hardware condition; determine needed action.
• Inspect wheels for cracks, damage and proper hand hold alignment.
• Check tire matching (diameter and tread) on single and dual tire applications.

Frame and Fifth Wheel

• Inspect fifth wheel mounting, bolts, air lines, and locks.
• Test operation of fifth wheel locking device; adjust if necessary.
• Check quarter fenders, mud flaps, and brackets.
• Check pintle hook assembly and mounting, if applicable.
• Lubricate all fifth wheel grease fittings and plate, of applicable.
• Inspect frame and frame members for cracks and damage.