Cooling and Lubrication System Maintenance Part 9 ppsx

You may go on to another task and Before installing a spin-on type oil filter, put a thin coat of clean oil on the gasket; this helps provide a good seal.. You should have said that you

The Joint Oil Analysis Program, a system designed to reduce

maintenance downtime and cost, was discussed You identified the benefits of the program, the publication used to determine major components that are covered in the program, and the methods used

to obtain the oil samples | |

The last subject that was covered was the inspection and testing procedures for the major components of the lubrication systems

As was stated earlier, the inspection and testing procedures

covered in this study unit are not all-inclusive, but are

provided as a guide The more you work with the equipment, the easier it will be for you to spot the problems that you have

covered in this study unit It's a good feeling when you know that you have correctly diagnosed and repaired a vehicle the

first time

Lesson 1 Exercise Solutions

Reference

Clean

Cool

Seal

Lesson 2 Exercise Solutions

Reference

b 3000 miles/semi-annually Fig 3-26

Lesson

1

2

3

4

5

6

7

‘Lesson

1

2

3

Lesson

1

2

3

4

5

6

7

9

10

11

3 Exercise Solutions

a Improper storage

b Improper handling

c Internal contamination

open container

Keep containers closed

oil

Allows unburned fuel to enter the crankcase

diluting the oil

Damaged head gasket

air filter

4 Exercise Solutions

a Reduces maintenance cost

b Reduces downtime

c Increases unit readiness

TI 4731-14/1

a Oil sampling pump

b Oil sampling valve

5 Exercise Solutions

Il

Iil

T1

classification

a Gaskets

b Hose connections

c Plugs and fittings

dad Seals

STE/ICE

TM-20 series

Breather valve

Cc

differential carrier cover

shaft, pump gears

Reference Lesson 3

3301

3301

3302

3303

3303

3303

Reference

3402

3403a

3403a

3403b

Reference 3501a 3501a 3501a 3501a 3501b 3501b 3501b 3501b 3502a 3502a 3503a

3504

3505 3505

STUDY UNIT 4 SERVICING THE LUBRICATION SYSTEM Introduction Properly servicing the lubrication system is one of the most important preventive maintenance tasks that you, aS an organizational mechanic, can do to prevent

failures For many years, the lube rack was on the bottom of the list for most mechanics as their preferred place to work The Marine Corps discovered, however, that when talented, well-trained Marines such as you are assigned to these

positions, there are fewer lubrication system related

maintenance problems

In this study unit, you will identify lubrication system

servicing techniques and procedures that will help extend the life of our equipment Additionally, you will identify

procedures for handling and disposing of used lubricants, parts, and shop materials

Lesson 1 LUBRICATION SERVICING (OIL)

LEARNING OBJECTIVES

1 Select the procedures for draining lubricants from major components

2 Select the procedures for cleaning parts

3 Select the procedures for installing parts

4 Describe in writing the steps for lubricating universal joints

5 State in writing the four key words to help recall the procedures for servicing wheel bearings

4101 Oil Changes

Have you ever heard a mechanic say, "I've been changing oil all

my life; I can do it in my sleep." Well, this type of attitude

is easily transferred into poor work and can cost the Marine

Corps a lot of money Mechanics have left oil drain plugs and oil filters loose In fact, they've even left dip sticks and oil caps off Don't laugh, it really happens Why does it happen? Because we've all been doing these tasks for a long time, and we take things for granted It's easy to make mistakes if we're not careful Let's discuss some important techniques and procedures that are often overlooked

a Draining Before actually draining the oil from any

reservoir, such as those for an engine or transmission, you

should operate the vehicle for a short period of time This

warms the oil and allows it to flow more smoothly It also helps remove impurities from the bottom of the oil pan; they will be drained out along with the oil Do NOT operate the equipment too long; the oil will get HOT If you were to splash hot 011 on yourself, you could be severely burned

Make sure that the container that you drain the oil into is large enough to hold the entire amount It's no fun trying to put a drain plug back in while the oil is still draining

When draining oil from an automatic transmission that doesn't have a drain plug, loosen the pan bolts so that one corner of the pan is lower than the others In this way, the oil will drain towards the low point After most of the oil has drained out, the pan can be removed When draining automatic transmissions, you may need a wide, deep pan to catch all t e oil

Use a strap wrench to remove spin-on type oil filters Don't try

to remove one with a screwdriver! Some mechanics poke a hole in the filter and use the screw driver as a lever to loosen it

Don't do this; you may damage the filter to the point that you can't remove it Make sure, too, to completely remove the old gasket material from the filter mounting surface

b Parts cleaning Metal parts are cleaned with either | petroleum or non-petroleum based cleaning solvents Don't clean seals, "0" rings, hoses, electrical connectors, or other plastic and rubber parts with petroleum-based cleaning solvent Clean these parts with soap and water or a non-petroleum based solvent and then dry them with a lint-free cloth Also be sure to clean parts in a well-ventilated area, wear skin and eye protection, and never use gasoline, kerosine, or diesel fuel as a cleaning agent

c Parts installation Reinstall oil drain plugs as soon as possible after draining components Before reinstalling a plug, check it Make sure that the threads aren't stripped and the head isn't rounded If the plug has a copper gasket, replace it

If it doesn't, coat the threads with pipe sealer The main point

to remember is to make sure that the plug is installed and

tightened after draining You may go on to another task and

Before installing a spin-on type oil filter, put a thin coat of clean oil on the gasket; this helps provide a good seal When installing the filter, first tighten it by hand and then use the strap wrench Don't make the filter too tight Normally about 2/3 of a turn after the filter base touches its mounting surface

is sufficient If you tighten the filter too tightly, you could damage the filter seal, causing leakage in this area or making the filter hard to remove during the next oil change

4-2

Automatic transmission internal filters are normally mounted on the bottom of the valve body which has a pickup tube to deliver the oil to the pump On these filters, an "0" ring is used to seal the pickup tube to the pump, preventing a loss of pressure When replacing the oil filter, make sure that the "0" ring is in place and be careful not to damage it during installation

ad Refilling the system Refilling the system isn't too

difficult Use the following steps to avoid problems

° Use the appropriate lubrication order to determine the types and quantities of lubricants

e Add clean oil A funnel sometimes makes life a lot

easier when refilling those hard-to-get-at components such as automatic transmissions

e Install the oil cap

e Check the 011 levels You may have to start the engine and bring the vehicle up to normal operating temperature Pay close attention to the level marks on the dip stick; some have a hot level and a cold level When reading the

"hot" level for transmissions and engines, the equipment must be at normal operating temperature

e Don't overfill components Excess oil could cause an increase in internal pressure, which in turn may result

in leaking seals and gaskets

Take a few minutes to check your work before sending the

equipment rolling out the door The few extra seconds that you spend looking for leaks and making sure that the job was done correctly could save you the price of a major component

On differential carrier assemblies and transfer cases, you check the oil level by removing the fill plug Use the lube order to determine the correct levels Most oil levels are maintained at

or near the bottom of the fill hole To get an accurate reading when checking these components, it's important to have the

vehicle on a level surface

Before continuing on, take a few minutes to apply what you have been learning by answering a few questions Write your answers in the spaces provided What do you do before actually draining any lubricants from a major component?

If you said, operate the equipment, you're correct

Now, why do you do this?

You should have said to warm up the lubricant If the

lubricant is warm, it will drain faster and also help remove impurities

What do you use to clean metal parts and rubber parts?

You should have said that you use either petroleum or non- petroleum based cleaning solvents to clean metal parts and

soap and water or a non-petroleum based solvent to clean

rubber parts

Now let's assume that you have just drained the oil out of an engine When should you reinstall the drain plug, and why should you do this?

If a drain plug is not equipped with a copper gasket you

When installing a spin-on oil filter, you should apply a

light coat of oil to the , tighten the filter by hand, and then tighten it an additional 2/3 of a turn with a

Your answers should be similar to the following:

The drain plug is reinstalled as soon after draining the oil

as possible This will keep you from forgetting about ‘it before you go on to the next task

It could also be a little bit embarrassing if you filled the engine with oil without the plug being installed You just might have a large puddle of oil to clean up too!

Pipe sealer is used on the threads of plugs that do not have gaskets

When installing a spin-on oil filter, you apply a light coat

of oil to the gasket and tighten the filter with a strap

wrench

If you had a difficult time answering any of these challenges, you should study paragraph 4101 again before continuing If you answered them correctly

KEEP ON TRUCKING!

4-4

4102 Lubrication Service (Greasing)

Most lubrication points and bearings are serviced periodically Wheel bearings are packed with grease, while most other

lubrication points have grease fittings that make the job simple and easy Some bearings are sealed and don't need lubrication, but they still need to be inspected

Many components, such as ball joints and constant velocity

universal joints, have rubber boots to protect them from

contaminants The boots should always be kept in place You should also unload ball joints before lubricating them; you do this by lifting the vehicle off the ground Unloading allows the joint to accept the grease much more easily

Dirt is the primary cause of universal joint failures Dirt

works away at the machined surfaces in much the same way that sand paper does Use the following procedures to properly

lubricate universal joints

e Clean the grease fitting before attempting to apply

grease

° Make sure the grease fitting adapter fits squarely on the fitting If it doesn't, the fitting may not accept

grease Components with fittings that are difficult to access are normally the first to fail For such lube points, use a flexible hose or universal grease fitting adapter on the grease gun

e Apply just enough grease to grease the joint; usually this is one or two pumps with a hand grease gun For components that have boots, don't fill the boot with

grease thinking that this will provide better lubrication

or make the grease last longer Overfilling could cause the boot to burst and leave the joint unprotected Avoid using pressure type lubrication pumps when greasing these components

° Replace any grease fittings that will not accept grease

e Clean the fittings of excess grease after lubricating This will prevent dirt buildup on the fitting

e Use the lube order and you won't miss any lube points! Let's get back to those wheel bearings As I stated earlier, wheel bearings, other than those that are sealed, must be packed with grease Why do the TM and LO require you to clean and

repack wheel bearings? Have you ever though about it?

The primary reason for cleaning and repacking the bearings is to remove contaminants and metal particles that accumulate from

normal wear If we didn't do this, even more wear would occur The advantage of sealed bearings is that no contamination can get

to the bearing to start the wear process Sealed bearings

therefore normally last longer than non-sealed bearings

Follow these procedures when servicing wheel bearings (Using the first words of each of the following statements will help you remember the procedures.)

Clean bearings with petroleum or non-petroleum based

cleaning solvents Dry them with a lint-free cloth

Don't use air pressure to dry bearings Doing this is dangerous; if a bearing is defective, it could fly apart! After drying, soak the bearing in oil this helps remove any solvent left from cleaning

Inspect bearings and races for discoloration and wear A blue color indicates that the bearing has been

overheated Check for scratches, grooves, or any other signs of wear If you discover any of these conditions, replace the bearing

Repack the bearing As you push grease into the bearing from one side, grease should push out the other side This also helps remove any oil and solvent left from

cleaning

Replace the wheel seals They protect bearings from

contamination, the primary reason for bearing failure

Be extremely careful when installing wheel seals; they are easily damaged Use the proper seal installation tool

Again, it's your turn to apply what you have been studying This time, in the space below, briefly describe the steps for

lubricating universal joints

Your answers should be similar to the ones below

Clean fittings before applying grease

Make sure the adapter fits the fitting

Apply just enough grease to lubricate the joint

Replace fittings that won't accept grease

Clean fittings after lubricating

Use the lubrication order and you won't miss any lube points

Now what are four "key words" to help you remember the procedures for servicing wheel bearings?

That's right, they are clean, inspect, repack, and replace

Lesson Summary In this lesson you identified procedures to

safely and correctly drain, clean, and refill components

containing oil and the procedures for servicing lubrication

points In the next lesson you will identify procedures for

disposal of used lubricants, parts, and shop materials

Exercise: Complete items 1 through 8 by performing the action

required Check your responses against those listed

at the end of this study unit

1 What should you do just before actually draining any

lubricant from a major component?

a Discontinue operation 24 hours before draining

b Operate the vehicle for a short period of time

c Remove the oil pick-up screen

d Remove all breather valves

2 For best results, lubricants should be drained when they are

a cold

b warm

c hot

3 What do you use to clean metal parts such as wheel

bearings?

a Brake fluid

b Diesel fuel

C Soap and water

d Non-petroleum based cleaning solvent

Rubber parts such as seals and "0" rings are cleaned with

a petroleum-based solvent

b soap and water

c brake fluid

ad gasoline

Before installing a drain plug that has a copper gasket, you should replace the gasket What do you do to a plug that is not equipped with a gasket?

a Coat the threads with pipe sealer

b Throw it away; drain plugs are always replaced

ec Install a lock washer

d Replace the plug without a gasket

What is the procedure for installing a spin-on type oil filter?

a Apply a light coat of grease to the seal Tighten the filter by hand as tightly as possible, and then, using a crescent wrench, tighten it an additional turn

b Apply a light coat of oil to the seal; tighten the filter by hand, and then tighten it an additional 2/3 turn with a strap wrench

c Clean the grease and 0il from the seal and then

tighten the filter by hand |

d Apply a light coat of oil to the seal, screw the

filter onto the adapter until resistance is felt, and then tighten an additional turn

Briefly describe the procedures for lubricating universal joints

f

What are the four key words that are used to help recall the procedures for servicing wheel bearings? -