DIET 1020 Syllabus

Subject Code

DIET

Course Number

1020

Course Title

Preventive Maintenance

Prerequisites

Prerequisite/Corequisite: DIET 1010

Corequisites

Terms Offered

Credit Hours

Course Description

This course introduces preventive maintenance procedures pertaining to medium and heavy duty trucks and heavy equipment. Topics include engine systems; cab and hood; heating, ventilation, and air conditioning; electrical and electronics; and frame and chassis.

Course Outcomes

Engine Systems

Observe 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 and belt alignment.
Check engine oil level, condition, and 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.
Check fuel systems tanks, mountings, lines, caps, and vents.
Drain water from the fuel syste4m
Perform service of the water separator/fuel heater.
Perform replacement of fuel filters.
Prime and bleed fuel system.
heck 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 (G\EGR) system and after treatment devices if equipped.
heck air induction system components (piping, charge air cooler, hoses, clamps, and mountings) for air restriction and leaks.
Inspect turbocharger for leaks as well as the mountings and connections.
Check operation of engine compression/exhaust brake.
Perform service or replacement of air filter as needed.
Check and reset air filter restriction indicator.
Inspect and service crankcase ventilation system.
Check operation of the fan clutch.
Inspect for air flow restrictions, leaks, and damage as well as its mountings.
Inspect fan assemble and shroud.
Perform pressure test of cooling system and radiator cap.
Inspect coolant hoses and clamps.
Inspect coolant recovery system.
Check coolant for contamination, additive package concentration, and protection level (freeze point).
Perform service of coolant filter.
Inspect water pump for leaks and earing play.
Perform and engine oil and filter change and visually check oil for coolant or fuel contamination.
Inspect and clean magnetic drain plugs.
Take an engine oil sample.

Cab and Hood Areas

Inspect key condition and operation of ignition switch.
Check warning indicators.
Check instruments and 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 diagnostic tool or on-board diagnostic system, retrieve engine monitoring information and check and record diagnostic codes and trip/operational data (including engine, transmission, ABS, and other systems).
Check operation of electric/air horns and reverse warning devices.
Check condition of spare fuses, triangles, fire extinguisher, and all required decals.
Inspect seat belts and sleeper restraints.
inspect wiper blades and arms.
Check operation of wiper and washer.
Inspect windshield glass for cracks or discoloration and check sun visors.
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 to components.
Perform lubrication of all cab and hood grease fittings.
inspect and lubricate door and hood hinges and latches, strikers, lock cylinders, safety latches, linkages, and cables.
Inspect cab mountings, hinges, latches, linages, and ride height.
Perform service as needed.

Heating, Ventilation, and Air conditioning (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, operation, land monitoring system if applicable.
Check HVAC air inlet filters and ducts.
Perform air inlet filter service as needed.

Electrical/Electronics

Inspect battery box(ex), cover(s)k, mountings, hold downs, connections, cables, and cable routing.
Perform battery component service as needed.
Check and record battery state-of-charge (open circuit voltage) reading and condition.
Perform battery test (load and/or capacitance).
Inspect starter mountings and connections.
Engage starter checking for unusual noises, starter drag, and starting difficulty.
Inspect alternator mountings, cable, wiring, and wire routing.
Perform alternator output tests.
Check operation of interior lights.
Check all exterior lights, lenses, reflectors, and conspicuity tape.
Check headlight alignment.
Inspect and test tractor-to-trailer multi-wire connectors, cables, and holders.

Frame and Chassis

Check operation of parking brake
Record air governor cut-out setting (psi).
Check operation of air reservoir/tank drain valves.
Check air system for leaks (brakes released and bakes applied).
Check overall air system for leaks.
Test one-way and double-check valves.
Check low air pressure warning devices.
Check air governor cut-in pressure.
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.
Perform lubrication of all brake component grease fittings.
Check condition and operation of hand brake (trailer) control valve.
Perform antilock brake system (ABS) operational system self-test.
Drain air tanks and check for contamination.
Check condition of pressure relief (safety) valves.
Check master cylinder fluid level and condition.
inspect brake lines, fittings, flexible hoses, and valves for leaks and damage.
Check parking brake operation inspecting application and holding devices; adjust as needed.
Check operation of hydraulic system (pedal travel, pedal effort, and pedal feel (drift).
Inspect calipers for leakage and damage.
Inspect brake assist system (booster), hoses, and control valves.
Check brake 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 (ABS) wiring, connectors, seals, and harnesses for damage and proper routing.
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.
Check clutch adjustment and adjust as needed.
Check transmission case, seals, filter, hoses, and cooler for cracks and leaks.
Inspect transmission breather and mounts.
Check transmission oil level, type, and condition.
Inspect u-joints, yokes, driveshaft, boots/seals, center bearings, and mounting hardware for looseness, damage, and proper phasing.
Inspect axle housings for cracks and leaks.
Inspect axle breathers.
Perform lubrication of all drive train grease fittings.
Check drive axle(s) oil level, type, and condition.
Perform drive axle oil and filter change and clean magnetic drain plug.
Check transmission wiring, connectors, seals, and harnesses for damage and proper routing.
Perform transmission oil and filter change and clean magnetic drain plug.
Check inter-axle differential lock operation.
Check range shift operation.
Check steering wheel operation for free play or binding.
Check power steering pump, mounting, and hoses for condition, leaks, and proper routing.
Check power steering fluid level.
Perform power steering fluid and filter change. Inspect steering gear for leaks and secure mountings.
Inspect steering shaft u-joints, pinch bolts, splines, pitman arm-to-steering sector shaft, tie rod ends, and linkages.
Check kingpin for wear.
Check wheel bearings for looseness and noise.
Check oil level and condition in all non-drive hubs.
Check for leaks in non-drive hubs.
Inspect springs, pins, hangers, shackles, spring u-bolts, and insulators.
Inspect shock absorvers for leaks and secure mounting.
Inspect air and leaf suspension springs, mounts, hoses, valves, linkages, and fittings for leaks and damage.
kCheck and record suspension ride height.
Perfrom lubrication of all suspension and steering grease fittings.
Check toe setting.
Check tandem axle alignment and spacing.
Check axle location components (radius, torque, and/or track rods).
Inspect tires for wear patterns and proper mounting.
Inspect tires for cuts, cracks, bulges, and sidewall damage.
Inspect valve caps and stems and replace as needed.
Measure and record tread depth and probe for imbedded debris.
Check and record air pressure.
Perform adjustment of tire air pressure in accordance with manufacturers' specifications.
Check for loose lug nuts.
Check wheel mounting hardware condition and service as needed.
Re-torque lug nuts in accordance with manufacturers' specifications.
Inspect wheels for cracks and damages.
Check for tire matching (diameter and tread) on dual tire installations.
Inspect fifth wheel mounting, bolts, air lines, and locks.
Test operation of fifth wheel locking device and adjust if necessary.
Check quarter fenders, mud flaps, and brackets.
Check pintle hook assemble and mounting.
Perform lubrication of all fifth wheel grease fittings and plate.
Inspect frame and frame members for cracks and damage.