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
Trang 2Lesson 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
Trang 3STUDY 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
Trang 4a 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
forget to install it! |
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
Trang 5Automatic 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?
Trang 6
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?
Metal
Rubber
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
should °
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
Trang 74102 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
Trang 8The 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
Trang 9Your 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?
They are , , ,and °
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
Trang 10Rubber 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 e f
What are the four key words that are used to help recall the procedures for servicing wheel bearings? -
a ,Đ ,Ce ,d
Trang 11Lesson 2 DISPOSAL OF USED LUBRICANTS, PARTS, AND SHOP MATERIALS LEARNING OBJECTIVES
1 State in writing the action to take if you don't know the specific procedures for handling or disposing of items such as oils, greases, solvents, or antifreeze
2 Given a situation describing the use of lubricants, parts, and shop materials, select the proper procedures for disposing of these products
3 Given an illustration of a motor pool that shows
violations of procedures for handling and disposing of used lubricants, parts, and shop materials, describe the violations in writing
During previous lessons, we discussed substances such as Oils, greases, solvents, and ethylene glycol antifreeze All of these substances require special consideration and handling to protect the environment During this lesson you will identify handling and disposal procedures and violations of these procedures Being unaware of these procedures is no excuse; doing the wrong thing, even unintentionally, could get you into serious trouble! 4201 Background
Reacting to the threat to human life and the natural environment presented by chemical wastes, both the Federal and various state governments have responded by enacting laws governing the
disposal of these wastes They have also imposed stiff penalties on illegally spilling or dumping toxic substances This means that if you don't dispose of toxic substances such as oil,
antifreeze, and battery acid correctly, you will be in violation of environmental laws Although these materials are familiar to us and we have used them for years in the motor pool, we should never forget that they are toxic and potentially harmful to the environment if they aren't disposed of properly!
Violations of environmental regulations are serious Consider these examples:
In some states, disposal of wastes such as acid or solvent that cause an environmental hazard is punishable by fines of up to $250,000 or by two years in prison, or both
Disposing of hazardous wastes at an unauthorized point, such as dumping solvent onto the ground behind the motor pool, in some states is punishable by a fine of up to $25,000 per day
Failure to report releases (spills) of hazardous substances into the environment is punishable by a fine of $10,000, one year in
Trang 12Does this information scare you? It should! The penalties for violating environmental laws are severe and the laws and
penalties vary from state to state Remember, too, that
procedures for handling waste products may vary What you may do legally in one state may be illegal in another and you personally may be held liable for violations
How do you protect yourself? That's easy You
e find out who your unit hazardous waste handler is and go to him or her when you are in doubt about the proper
procedures for handling hazardous wastes This Marine is your trained unit representative who can answer your
questions concerning hazardous waste
e become familiar with the hazardous waste and material laws and regulations in the state to which you are assigned
e become familiar with the laws and regulations for the states or countries that you may be deploying to or are working in
Now, what should you, as a mechanic, do if you don't know the proper procedures for disposing of used waste materials? If you
said contact your hazardous waste handler, you're right on track 4202 Disposal and Handling Procedures
a Disposal and handling of oils and lubricants Normally, a designated collection point for used motor oil, gear oil, and transmission fluids is provided This collection point is usually located in the motor pool and it could consist of oil sumps, large tanks, or 55 gallon drums for the storage and
disposal of lubricants Procedures for handling and disposal of the oils and lubricants include the following:
e You can place most oils, for example, engine oil, gear oil, and transmission fluid in the same container
(collection point)
e Don't mix solvents or fuels with the oil
e Be sure that the contents are clearly marked on the container
Trang 13e Leave a 4 inch head space at the top of drums or tanks to allow for expansion from heat
e Keep the POL storage area clean and orderly
e Report oil spills to your unit hazardous waste handler Any instance of non-compliance with the previous procedures is
considered a violation! |
b Disposal and handling of cleaning solvents Most units are using a bio-degradable cleaning solvent in place of the once widely used dry cleaning solvent This makes disposal of the solvent easy and economical Dry cleaning solvent, however, must be disposed of in clearly marked containers Don't mix other lubricants or liquids with cleaning solvents
In many states, bio-degradable cleaning solvents can be disposed of through the sewer pipes IF those pipes are connected to a sanitary sewer waste disposal system This type system is not a leach field (septic tank) system If you don't know what type of system your unit has, check with the hazardous waste handler If the system is not connected to an approved disposal system, you must dispose of the solvent, bio-degradable or not, in a clearly marked container
Take care when using bio-degradable cleaning solvents Remove most of the dirt from parts before placing them in the cleaning tank Doing this will prevent a build-up of sludge in the bottom of the tank If the cleaning solvent contains any sludge, the solvent is no longer considered bio-degradable It must be considered contaminated and disposed of as hazardous waste Avoid using buckets, coffee cans, and drain pans for cleaning parts These containers have a way of ending up in a corner or being scattered throughout the shop and are prime targets for fines from Environmental Protection Agency inspectors While operating in the field, you may have to use pans or buckets to clean parts; use them only when necessary and empty them
immediately after use
c Disposal and handling of ethylene glycol antifreeze In some states, ethylene glycol can be disposed of through a sanitary sewer waste disposal system It's important to remember to flush the antifreeze down the drain with an equal amount of water; this will adequately dilute the chemical If you are disposing more than five gallons at any one time, notify your hazardous waste handler This is important because there may be other
requirements, or you may need prior approval
If your unit is not connected to an approved system, you must have a clearly marked disposal container Never dispose of
Trang 14*#k* NEWS FLASH *%*
In some units, ethylene glycol is being recycled right now! You may soon be required to take it to a recycling collection point so stay in touch with your unit hazardous waste handler for any updates
ad Disposal and handling of oil filters, oil cans, and oil filled parts In many cases, used oil filters, oil cans, and parts containing oil, such as oil coolers and oil pumps, are as big a problem as the the oil itself These items must be
completely drained before they are disposed of Place oil filters in plastic bags before putting them in a solid waste container As always, check with your hazardous waste handler for disposal ˆ requirements if you don't know the proper procedures The laws governing the handling of solid wastes are not always the same in each state Take some advice and make that hazardous waste
handler a regular on your list of frequent stops e Disposal of dry sweep and rags
(1) Dry Sweep Dry sweep is used to clean up oil spills Being an extremely absorbent compound, it can absorb up to ten times its weight in liquid and should be used
until it can no longer absorb any more liquid Dry sweep that is still useable should be kept in a resealable open head 55 gallon drum Put a screen on the top of the drum to keep trash out of the dry sweep After the dry sweep has reached its useful life, seal the drum and clearly mark it as "dry sweep contaminated with oil."
(2) Rags In many units, shop rags are handled through a contractor who picks up dirty rags and exchanges them for clean ones The contractor then disposes of rags too dirty to be cleaned at his facility If your unit is in this program, all you have to do is keep the rags ina covered metal container On the other hand, if your unit hasn't come on line with this service, you must handle rags as hazardous waste Store the used rags ina 55 gallon resealable drum Mark the drum clearly with its contents and be sure that the drum lid is in place when the drum isn't being used Rags contaminated with dry cleaning solvent must be kept separately from oil soaked rags and must also be disposed of as hazardous waste OK, let's see how sharp you are Read the statements below and determine if the practices described violate handling or disposal procedures Circle the violations
1 Engine and gear oil placed in the same container 2 Oil and solvent placed in the same container 3 Keeping used oil containers sealed
Trang 154 Oil drums leaking on the POL rack
5 Oil pans and containers stored in out-of-the-way corners of the motor pool
6 Oil filters being placed in plastic bags and then placed in the solid waste container
7 Pouring antifreeze into a drainage ditch or a stream 8 Disposing of solvent-soaked rags as hazardous waste 9 Maintaining dary sweep in an open container
You should have circled numbers 2,4,5,7 If you missed any of these items, review paragraph 4202 before completing the lesson exercise
Lesson Summary During this lesson you identified procedures for disposing of lubricants and other liquid and solid waste materials that you must deal with on a daily bases You also identified violations of these procedures As stated earlier, some of these procedures and violations may vary from state to state Your unit has an individual who is responsible for
keeping up with the latest changes in the environmental laws and regulations; this is your unit's hazardous waste handler
Consult this person when you don't know the proper disposal procedures and to keep you up to speed on the latest changes in the laws and regulations Remember, everyone is responsible for the environment We either take care of it now, or it won't be here in the future
Exercise: Complete items 1 through 5 by performing the action required Check your responses against those listed at the end of this study unit
1 What action do you take if you don't know a specific procedure for handling or disposing of oils, greases, solvents, or antifreeze?
Items 2 through 4 refer to the situation that follows Read the Situation carefully, then answer the items
Situation: While on a field exercise, a five-ton truck (M923) was brought into the maintenance area for corrective maintenance The transmission oil pan gasket was leaking The transmission oil was drained, the oil pan removed and cleaned using dry cleaning solvent and rags, and the
transmission filter was inspected and replaced The
Trang 16Which procedure is used to dispose of the used oil and the cleaning solvent that was used to clean the oil pan? a b da Dispose of both the solvent and the oil in the oil collection point
Dispose of the oil at the oil collection point and
dispose of the solvent by diluting it with equal amounts of water and dumping it 50 feet away from Maintenance area
Dispose of the oil in the oil collection point and the solvent in the separate container marked
"solvent."
Dispose of both the oil and the solvent in the hazardous waste container
Which procedure is used to dispose of the old oil filter? Dispose of it in the scrap metal bin
Place it ina plastic bag and dispose of it in the solid waste container
Place it ina plastic bag and dispose of it in the liquid waste container
Place it in a separate container and dispose of it as hazardous waste
Which procedure is used to dispose of the solvent soaked rags used to clean the oil pan?
Dispose of them in the used rag bin
Keep them separate from the other used rags and dispose of them as hazardous waste
Dry them and use them again
Bury them 50 feet from the maintenance area
Trang 17Item 5 refers to the figure below Review the picture carefully with plenty of water Mar wife c2) É3 — lan ca sad —/ Se sate `" - LX 4402 GA GA
5 Find the violations of proper waste handling and disposal procedures shown in the figure above Describe the