Unit 3: Maintenance Unit 3: Maintenance and Safety Checksand Safety Checks

What Does a Battery Work?What Does a Battery Work? Function:Function:

Stores electrical energy inside of cells.Stores electrical energy inside of cells. How:How:

Battery Contains Sulfuric acid/water combination. Battery Contains Sulfuric acid/water combination. When discharged (used), electrolyte solution When discharged (used), electrolyte solution

becomes more diluted.becomes more diluted. When charging (either on charger or alternator), When charging (either on charger or alternator),

electrical energy is converted to chemical energy electrical energy is converted to chemical energy & sulfuric acid/water solution becomes more & sulfuric acid/water solution becomes more concentrated.concentrated.

Using Jumper Cables…Using Jumper Cables… First Connect the Positive post of the First Connect the Positive post of the

(good)booster battery, then the Positive (good)booster battery, then the Positive post of the Dead battery.post of the Dead battery.

From http://www.cyb.co.nz/automotive/batt_facts/jumpstart.htm

Dead Battery

Good Battery

Using Jumper Cables Using Jumper Cables ContinuedContinued

Next connect the negative post of the Next connect the negative post of the booster battery, then connect the cable booster battery, then connect the cable to a good ground away from the battery to a good ground away from the battery on the dead machine.on the dead machine.

From http://www.cyb.co.nz/automotive/batt_facts/jumpstart.htm

Good Battery

Dead Battery

How important is Oil?How important is Oil?

Extremely Important! Extremely Important!

4 Main Functions of Oil:4 Main Functions of Oil: Reduces friction of moving partsReduces friction of moving parts Carries heat away from engine.Carries heat away from engine. Creates seal between piston and Creates seal between piston and

cylinder wall.cylinder wall. Keeps engine clean.Keeps engine clean.

Oil Viscosity:Oil Viscosity:

The viscosity grade (for example, SAE 30 or a Multigrade oil like 5W-30) tells you the oil's thickness, or viscosity. A thin oil has a lower number and flows more easily, while thick oils have a higher number and are more resistant to flow.

Water has a very low viscosity -- it is thin and flows easily. Honey has a very high viscosity -- it is thick and gooey.

Most oils on the shelves today are "Multigrades", which simply means that the oil falls into 2 viscosity grades (i.e. 10w-40)

Multigrades were first developed some 50 years ago to avoid the old routine of using a thinner oil in winter and a thicker oil in summer.

In a 10w-40 for example the 10w (W = winter, simply means that the oil must have a certain maximum viscosity/flow at low temperature. The lower the "W" number the better the oil's cold

temperature/cold start performance.

Fuel Systems:Fuel Systems: Gasoline:Gasoline:

Fuel Tank Fuel Tank Carburetor Carburetor Spark Plugs Spark Plugs EngineEngine

Diesel:Diesel: Fuel Tank Fuel Tank Pump & Injectors Pump & Injectors EngineEngine

Both have very small passageways for fuel movement. Important that fuel be kept free of dirt & water.

http://www.youtube.com/watch?v=IYWUWMmimjQ

http://www.youtube.com/watch?v=JgbuE1FT5Ks

Hydraulic SystemHydraulic System Works through set of hydraulic rams pulling & Works through set of hydraulic rams pulling &

pushing.pushing.

Problems can be attributed to:Problems can be attributed to: 1 Not enough oil in reservoir.1 Not enough oil in reservoir. 2). Dirty/clogged filter.2). Dirty/clogged filter. 3). Leaking connections.3). Leaking connections. 4). Incorrect oil in system.4). Incorrect oil in system.

Milky colored= water in system. Milky colored= water in system.

Clean quick couplers before connecting. Clean quick couplers before connecting.

http://videos.howstuffworks.com/discovery/31562-massive-engines-hydraulic-diggers-video.htm

Lubricating moving partsLubricating moving parts

Use correct type of grease & wipe Use correct type of grease & wipe fittings to remove debris before fittings to remove debris before attaching grease gun.attaching grease gun.

Maintain Clutch-Free TravelMaintain Clutch-Free Travel ½” – 2” of clutch movement is ½” – 2” of clutch movement is

normal.normal. May burn out if not maintainedMay burn out if not maintained

What is Maintenance?What is Maintenance?

Proper Prevention Prevents Poor Proper Prevention Prevents Poor Performance…Performance…

In this section, we will In this section, we will discuss:discuss:

Daily Maintenance Daily Maintenance ChecksChecks

Preventive Preventive Maintenance Maintenance ScheduleSchedule

Maintenance Maintenance Systems and ChartsSystems and Charts

Maintenance Maintenance OperationOperation

Daily MaintenanceDaily Maintenance FOUR REASONS FOR DAILY MAINTENANCE:FOUR REASONS FOR DAILY MAINTENANCE:

1.1. Reduces Tractor and Machine StoppagesReduces Tractor and Machine Stoppages

2.2. Reduces Equipment Safety HazardsReduces Equipment Safety Hazards

3.3. Reduces Operation CostReduces Operation Cost

4.4. Increases Service LifeIncreases Service Life

Preventive Maintenance Preventive Maintenance ScheduleSchedule

4 WAYS/TYPES OF HOW A PREVENTATIVE 4 WAYS/TYPES OF HOW A PREVENTATIVE MAINTENANCE SCHEDULE IS KEPT: MAINTENANCE SCHEDULE IS KEPT: 1.1. Schedule Maintenance By Hours (10, 50, 100, 250, Schedule Maintenance By Hours (10, 50, 100, 250,

etc)etc)2.2. Seasonal Checks or Yearly ChecksSeasonal Checks or Yearly Checks3.3. Date and Hours of Machine when Service or Date and Hours of Machine when Service or

Maintenance is Completed.Maintenance is Completed.4.4. Any Additional Records (Oil, Fuel, Repair Cost)Any Additional Records (Oil, Fuel, Repair Cost)

Maintenance Systems And Maintenance Systems And ChartsCharts

Used to find out when suggested Used to find out when suggested maintenance and lubrication should be maintenance and lubrication should be done.done.

Maintenance Operation-Maintenance Operation- (found in operator’s (found in operator’s manual)manual)

(Look @ ~pg. 27 for details)(Look @ ~pg. 27 for details)

Air CleanerAir Cleaner Keep Clean- 9,000 gal. of air drawn into engine for every gal. of Keep Clean- 9,000 gal. of air drawn into engine for every gal. of fuel. Air must be free of foreign materials if engine to function fuel. Air must be free of foreign materials if engine to function w/out excessive wear.w/out excessive wear.

BatteryBattery Keep charged, check electrolyte levels every 50 hours of use.Keep charged, check electrolyte levels every 50 hours of use.

Clutch-free Clutch-free TravelTravel

½ in- 2in of clutch free travel normal. Clutch can burn out if not ½ in- 2in of clutch free travel normal. Clutch can burn out if not maintained.maintained.

Crankcase OilCrankcase Oil Check oil level daily, change oil filter when changing oilCheck oil level daily, change oil filter when changing oil

Fuel SystemFuel System Keep fuel away from water & dirt- can get stuck in narrow fuel lines Keep fuel away from water & dirt- can get stuck in narrow fuel lines causing blockages. Keep machine fueled & service fuel filter causing blockages. Keep machine fueled & service fuel filter regularly. regularly.

Hydraulic Hydraulic SystemSystem

Check hyd. Oil every 50 hours, replace every 1200 hours. Clean Check hyd. Oil every 50 hours, replace every 1200 hours. Clean filter. Milky=water, Leaks=air in linefilter. Milky=water, Leaks=air in line

LubricationLubrication Lube move parts every 50 hours, wipe fitting before greasingLube move parts every 50 hours, wipe fitting before greasing

TransmissionTransmission Check 1x/week, replace every 2 years. Checked by removing trans. Check 1x/week, replace every 2 years. Checked by removing trans. Dipstick or plugDipstick or plug

Power TakeoffPower Takeoff Check oil every 50 hours, make sure shields are in placeCheck oil every 50 hours, make sure shields are in place

Cooling SystemCooling System Check coolant level every 10 hours, check for leaks, change Check coolant level every 10 hours, check for leaks, change antifreeze 1x yearantifreeze 1x year

TiresTires Overinflated- excessive wear. Overinflated- excessive wear.

Underinflated- Excess flexing, heating, and premature wearUnderinflated- Excess flexing, heating, and premature wear

Tires…Tires… Can add ballast (weight) to Can add ballast (weight) to

improve traction.improve traction. Too much weight-no evidence of Too much weight-no evidence of

tread slippagetread slippage Too little weight-too much slippageToo little weight-too much slippage 10%-15% slippage is ideal.10%-15% slippage is ideal.

Types of Ballast Material Types of Ballast Material Type Cost

Freeze Resist

Weight vs. Water

Safe? Availability

Water free none +0% very safe wide

Calcium Chloride low -50F +40%

Corrosiveorrosive(need to

put in tubes)

wide

Ethylene Glycol Antifreeze

medium -40F +0% toxic wide

Propylene Glycol Antifreeze

high -40F +0% safe wide

Windshield Washer Fluid

low -20F +0% toxic wide

Beet Juice(i.e. Rim Guard)

very high -35F +30% very safedealer

network

Polyurethane Foam/Flat Fill

very high +20-50% very safedealer

network

The Daily Maintenance The Daily Maintenance Check:Check:

Check: Check: Fuel SupplyFuel Supply Radiator Coolant LevelRadiator Coolant Level Tire PressureTire Pressure Battery Fluid LevelBattery Fluid Level Crankcase Oil Level- Crankcase Oil Level- oil level may decrease oil level may decrease

over time…over time…

The Safety Check- The Safety Check- When a tractor is serviced, check for safety When a tractor is serviced, check for safety

hazards like loose belts, worn/broken/damaged hazards like loose belts, worn/broken/damaged parts, & dirt accumulation. Also check:parts, & dirt accumulation. Also check:

Seat Position and Seat Position and SecuritySecurity

Steering ConnectionsSteering Connections Hitch Hitch Tires and WheelsTires and Wheels Platform (no loose Platform (no loose

objects)objects) Steps and handholds Steps and handholds Brake Pedal locking Brake Pedal locking

function worksfunction works Attached EquipmentAttached Equipment Ignition WiringIgnition Wiring

Assignment: Assignment:

Unit 3: Pg. 37 (1-10)Unit 3: Pg. 37 (1-10)

Optional Enrichment Assignment for Success: Pg. Optional Enrichment Assignment for Success: Pg. 3636 Maintenance & Safety ChecksMaintenance & Safety Checks