DPE 4030 - Hydraulics

Safety

• 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.

Hydraulic Systems

• Identify system type (closed and open) and verify proper operation.
• Read and interpret system diagrams and schematics.
• Perform system temperature, pressure, flow, and cycle time tests; determine needed action.
• Verify placement of equipment /component safety labels and placards; determine needed action.

Pumps

• Identify system fluid type.
• Identify causes of pump failure, unusual pump noises, temperature, flow, and leakage problems; determine needed action.
• Determine pump type, rotation, and drive system.
• Remove and install pump; prime and/or bleed system.
• Inspect pump inlet for restrictions and leaks; determine needed action.
• Inspect pump outlet for restrictions and leaks; determine needed action.

Filtration/Reservoirs

• Identify type of filtration system; verify filter application and flow direction.
• Service filters and breathers.
• Identify causes of system contamination; determine needed action.
• Take a hydraulic oil sample for analysis.
• Check reservoir fluid level and condition; determine needed action.
• Inspect and repair or replace reservoir, sight glass, vents, caps, mounts, valves, screens, supply and return lines.

Hoses, Fittings, and Connections

• Diagnose causes of component leakage, damage, and restriction; determine needed action.
• Inspect hoses and connections (length, size, routing, bend radii, and protection); repair or replace as needed.
• Assemble hoses, tubes, connectors, and fittings in accordance with manufacturers’ specifications; use proper procedures to avoid contamination.
• Inspect and replace fitting seals and sealants.

Control Valves

• Pressure test system safety relief valve; determine needed action.
• Perform control valve operating pressure and flow tests; determine needed action.
• Inspect, test, and adjust valve controls (electrical/electronic, mechanical, and pneumatic).
• Identify causes of control valve leakage problems (internal/external); determine needed action.
• Inspect pilot control valve linkages, cables, and PTO controls; adjust, repair, or replace as needed.

Actuators

• Identify actuator type (single/double acting, multi-stage/telescopic, and motors).
• Identify the cause of seal failure; determine needed repairs.
• Identify the cause of incorrect actuator movement and leakage (internal and external); determine needed repairs.
• Inspect actuator mounting, frame components, and hardware for looseness, cracks, and damage; determine needed action.
• Remove, repair, and/or replace actuators in accordance with manufacturers’ recommended procedures.
• Inspect actuators for dents, cracks, damage, and leakage; determine needed action.
• Purge and/or bleed system in accordance with manufacturers’ recommended procedures.