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LEARNING OUTCOME NO. 3 PREPARE EQUIPMENT REPORT Contents: 1. Principle and procedures in accomplishing Daily Preventive Maintenance Checklist in accordance with manufacturer’s / company requirements 2. Reports on the Major/Minor Equipment Defects of Hydraulic Excavator Assessment Criteria 1. Daily checklist form is properly accomplished in accordance with manufacturer’s/company requirements 2. Minor/major equipment defects are reported to concerned personnel
Conditions The students/trainees must be provided with the following: 1.WORK PLACE LOCATION 2.EQUIPMENT -
Computer/Laptop LCD
3.TOOLS, ACCCESSORIES AND SUPPLIES -
Whiteboard CD Tapes
4.TRAINING MATERIALS -
Learning Packages Ball pens Whiteboard Markers Manuals / Handouts Daily Preventive Maintenance Checklist Report Sheet / Log Sheet for Equipment
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 1 of 37
Assessment Method: Written and/or oral questionings Direct observation/Practical demonstration Work record and documents
Learning Experiences Learning Outcome 3 PREPARE EQUIPMENT REPORTS Learning Activities
Special Instructions
1. Read Information Sheet 2.3-1 – Principles and Procedures of Daily Preventive Maintenance Checklist in accordance with manufacturer’s/company requirements
Read and understand the information sheet 2.3-1 on “Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist”
You must answer all the questions correctly before proceeding to the 2. Answer Self-Check 2.3-1 next activity. You can ask the Compare answers to Answer Key assistance of your trainer for further explanation regarding the 2.3-1 topic that you may not understand. 3. View the Power Point on Principles and Procedures of Daily Preventive Maintenance Checklist Answer the trainer’s question 4. Perform Task Sheet 2.3-1 – on Preparing Daily Preventive Maintenance
Listen and understand the power lecture or point presentation on “Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist”
Use appropriate tools, instruments, equipment, supplies and/or materials. Task sheet will help you practice your skills. The performance criteria checklist 2.3-1 on “Principles and Procedures
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 2 of 37
in Accomplishing Daily Preventive Maintenance Checklist” will guide and help you evaluate your work as you are practicing your skill. Evaluate your own work using the performance checklist. When you are ready, present your work to your trainer for final evaluation and training. Ask trainer if you can proceed to the next learning outcome.
5. Evaluate your output using Performance Criteria Checklist 2.3-1
6. Read Information Sheet 2.3-2 – Report Minor / Major Equipment Defects of Backhoe Loader
Read and understand the information sheet 2.3-2 on “Report Minor / Major Equipment Defects of Backhoe Loader”
7. Perform Task Sheet 2.3-2 – in Preparing Report Minor / Major Equipment Defects of Backhoe Loader
Use appropriate tools, instruments, equipment, supplies and/or materials. Task sheet will help you practice your skills. The performance criteria 2.3-2 on “Report Minor Equipment Defects of Loader” will guide and evaluate your work as practicing your skill.
checklist / Major Backhoe help you you are
Evaluate your own work using the performance checklist. When you are ready, present your work to your trainer for final evaluation and training. Ask trainer if you can proceed to the next Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 3 of 37
learning outcome.
8. Evaluate your output using Performance Criteria Checklist 2.3-2
Information Sheet 2.3-1 Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the principles and use of Daily Preventive Maintenance Checklist 2. Identify the procedures in accomplishing the Daily Preventive Maintenance Checklist In LO 2 of Module Performing Basic Preventive-Maintenance for Backhoe Loader Operation you learned to perform basic preventive maintenance servicing (PMS). You learned to identify the OS parts/ standards according to manufacturer’s recommendation including the basic hand tools and equipment to be used in accordance with site requirements. In this module you will learn the principles and procedures in accomplishing the Daily Preventive Maintenance Checklist. Below is the step-by-step guide Maintenance of Hydraulic Excavator.
in
performing
the
Routine
LEGEND
Visual Inspectionobserve safety procedures Very Important! Regularly check these items. Caution: Observe safety procedures at all times Report any unusual noise immediately
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.1 Accumulator: Handling and releasing pressure
Activity Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
Materials
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(minutes)Duration
Activity Number 1 2 3 4
5 6 7 8
Lower the attachment completely to the ground. Keep all the attachments, such as hammer, closed. After turning off the engine, turn the ignition key to running position. Move the control lockout lever up to unlock the hydraulic system. To release the pressure in the control circuits and accumulator, move the operating levers and pedals forward/reward and left/right to their respective end positions. Turn the ignition key to stop position. Move the control lockout lever down to lock the hydraulic system securely. To release the pressure completely, loosen the hose connection slowly when you disconnect the accumulator. Step aside in this case as oil should spurt out.
TOTAL
Tool Class
No. of Unit
No. of Unit
Material
1.0 1.0 1.0 1.0
1.0 1.0 1.0
Caution: Observe safety procedures at all times.
Visual Inspectionobserve safety procedures
1.0 8.0
IMPORTANT: The accumulator is charged with highly pressured nitrogen gas. Handle it with care. Otherwise, it can cause serious accidentals or injuries.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader
Activity
3.2 Before starting: checkpoints (minutes)Duration
Activity Number
Maintenance Activity:
Tools
Tool Class
Materials No. of Unit
Material
Visual Inspection-observe safety procedures 1-pc
1
Check oil and water leak.
1.0
2
Check and retighten nuts and bolts.
3.0
3
Check electric wiring.
3.0
4
Check and supply coolant.
3.0
DO3 fluid
5
Check and supply engine oil.
3.0
Engine oil
6
Check and supply fuel.
3.0
7
Drain water and sediment of fuel tank.
3.0
8
Check and supply brake fluid.
3.0
9
Check steering wheel play.
1.0
10
Check and adjust brake pedal travel.
5.0
11
Check and adjust braking ability.
5.0
12
Check and adjust parking brake lever travel.
5.0
13
Check and adjust tire pressure.
5.0
14
Check dust indicator.
1.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Wrench Pliers, Electrical tape
No. of Unit
1-pc
Visual Inspectionobserve safety procedures
Pressure gauge
Date Developed:
1-pc
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.2 Before starting: checkpoints (minutes)Duration
Activity Number
Maintenance Activity:
Activity
15
Check lamps.
1.0
16
Check horn.
1.0
17
Check exhaust gas color.
1.0
18
Check instruments.
1.0
19
Check previous day’s defects.
1.0
20
Check door lock.
3.0
21 22
Check wiper, window washer and defroster. Inspect float position of water separator. TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Visual Inspectionobserve safety procedures
Logbook
2.0
Visual Inspectionobserve safety procedures
2.0 56.0
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.3 Engine oil level: Check/top-up (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Turn on the engine until it reaches operating temperature.
3.0
2
Turn off engine. Wait for a few minutes for the oil to drain back into the oil pan.
5.0
3
Pull out the dipstick and wipe it clean cloth.
0.5
4
Inspect the dipstick and pull it out again. It should be between the High and Low mark. If the oil is below the Low mark, remove the oil filler cap and pour recommended oil.
2.0
5
Recheck oil level with dipstick.
0.5
TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures Visual Inspectionobserve safety procedures
Screw driver
1-pc
SAE 30
1 liter
Visual Inspectionobserve safety procedures
11.0
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.4 Engine coolant: Change
1
2
3 4
5
Activity
Open the heater water cock. Manual air conditioning: move the temperature control lever to maximum hot position. Automatic air conditioning: turn the ignition switch On and move the temperature control lever to the maximum hot position.
Open the radiator cap and drain valve Open the drain plug on the engine block for the diesel engines. Flush the cooling system by running fresh water through the radiator. Securely close the drain valve (and drain plug for diesel engines). Fill the radiator with the proper mixture of coolant and water. Fill the reservoir tank up to the maximum level. The install the radiator cap.
(minutes)Duration
Activity Number
NOTE: Wait until the engine and radiator cool down. Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Caution: Observe safety procedures at all times. 2.5
2.5
5.0
Monkey wrench
1-pc
5.0
Pressurized water hose
1 assy
Drain pan
1-pc
1.0
10.0
Visual Inspectionobserve safety procedures
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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for Heavy Equipment Operation Backhoe Loader 3.4 Engine coolant: Change
Activity Number
(minutes)Duration
Maintenance Activity:
Activity
6
Start the engine and war it up until it reaches normal operating temperature. Then race the engine 2 or 3 times under no load. Watch the coolant temperature gauge for sign of overheating.
7
Stop the engine after it completely cools down. Refill the radiator up to the filler opening. Fill the reservoir tank up to this maximum level.
15.0
8
Check the drain valve (and drain plug for diesel engines) for any sign of leaks.
1.0
TOTAL
62.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
20.0
Date Developed:
Visual Inspectionobserve safety procedures
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.5 Engine coolant level: Check/top-up (minutes)Duration
Activity Number
Maintenance Activity:
Activity
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
1-pc
1
Wait until the engine and radiator cool down.
3.0
2
Open the radiator cap and drain valve.
1.0
Drain pan
3
Flush the cooling system by running the fresh water thru the radiator.
3.0
Soft water
4
Securely close the drain valve.
0.5
5
Fill the radiator with the proper mixture of coolant and water. Fill the reservoir tank to level. Tightly close the radiator tank.
6
Start the engine and warm it up until it reaches normal temperature.
3.0
7
Check the drain valve for possible leaks.
0.5
TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
3.0
Soft water 70% Anti-freeze solution 30% Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
14.0
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.6 Fuel tank: drain
(minutes)Duration
Activity Number
NOTE: If the equipment runs with fuel of low quality, the fuel tank needs to be drained.
Activity
1
Place a suitable sized container under drain hose.
1.0
2
Open the drain valve cap at the bottom of the tank.
2.0
3
Open the filler cap.
0.5
4
Connect the drain hose and drain off any sediment.
4.0
5
Disconnect the drain hose and install the valve cap again.
2.0
6
Close the filler cap
0.5 TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Drain pan
1-pc
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
10.0
IMPORTANT: Take care of filter/ oil/ liquids in an environmentally safe way.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 14 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.7 Fuel system: Air bleeding
Activity Number
(minutes)Duration
NOTE: Air must be bled out the fuel injection system whenever the machine runs out of fuel while the engine is running.
Activity
1
Turn priming pump counterclockwise to unlock the plunger.
1.0
2
Push priming pump until a heavy resistance can be felt in the priming pump.
3.0
Push priming pump fully and turn it clockwise to lock the plunger.
1.0
3
4
Start the engine and let it run idle for 3 minutes.
3.0
5
If the engine is difficult to start, repeat (1) to (3).
5.0
6
Check for any leaks.
1.0 TOTAL
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
14.0
IMPORTANT: Do not attempt to start the engine under any circumstances until the air in the system has been bled out completely otherwise the injection pump may be seriously damaged.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 15 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.8 Hydraulic system: Releasing pressure (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Place attachment on the ground and shut down engine.
5.0
2
After engine is shut down, turn ignition key to running position (Do not start engine).
0.25
3
4
Keep the control lockout lever up (unlocked position) and move all control levers and pedals to release main system pressure from all lines. Turn ignition key to off position. Remove the key and tag the machine to indicate that the unit is under service.
Tool Class
1.0
1.0
5
Lower the control lockout lever (locked position).
1.0
6
Press the pressure relief valve located on the hydraulic tank breather valve to release tank pressure.
1.0
TOTAL
Tools
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
9.25
IMPORTANT: Release the internal pressure of the tank and hydraulic lines before removing any components of hydraulic system. Otherwise leakage may cause high pressure to build up in the hydraulic circuit. If the work cannot be completed within a short time after the system was released, the system pressure must be released again.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 16 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.9 Hydraulic oil level: check (minutes)Duration
Activity Number
NOTE: When refilling the oil, use the same oil as the system is filled with.
Activity
1
Park the machine in service position.
1.0
2
Move the control lockout lever down to lock the system securely and stop the engine.
1.0
3
4
Open the side door on the right side of the machine and check the oil level in the sight gauge. If the level is in the center of the gauge, the level is correct. If the level is low, - press breather to release the internal pressure at the tank - unscrew the bolts - remove the cover and spring - top up the oil. Top up the oil efficiency press air breather again - check the level.
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
2.0
0.5 2.0 2.0 5.0
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
1.0 5
If the level is normal, clean the dismantled parts and install.
6
If the level is high, - place a suitable sized contained under the hydraulic tank - removed the protecting cap and attach drain hose which is the same hose as that used for draining engine oil - drain the oil into a container. TOTAL Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
0.25
Drain pan
1-pc
1.0 1.0
5.0 21.75 Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 17 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.10 Machine set-up for maintenance: Primary work (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Park on firm, level ground
2.0
2
After engine is shut down, turn ignition key to running position (Do not start engine).
0.25
3
4
Keep the control lockout lever up (unlocked position) and move all control levers and pedals to release main system pressure from all lines. Turn ignition key to off position. Remove the key and tag the machine to indicate that the unit is under service.
1.0
Set level on lock position.
0.5
6
Before starting maintenance work, hang up a tag on cap door or work lever.
1.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tool Class
1.0
5
TOTAL
Tools
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
9.75
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 18 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.11 Radiator, oil cooler and condenser Fins (cooling system): clean
Activity Number
(minutes)Duration
NOTE: Wear safety googles or a face mask. Do not use steam to clean the air conditioner condenser.
Activity
1
Remove any mud or dust attached to the radiator find and oil cooler fins with compressed air.
5.0
Pressurized air cleaner
1-pc
2
Clean radiator and oil cooler with compressed air after detaching the clogging nets.
5.0
Pressurized air cleaner
1-pc
3
Clean the gap between oil cooler and radiator with compressed air after opening engine hood.
5.0
Pressurized air cleaner
1-pc
4
Clean the radiator with compressed air after detaching the air conditioner.
5.0
Pressurized air cleaner
1-pc
5
Check the rubber hose for wear and cracks. If damaged, replace it. Check loose hose clamps. TOTAL
Tools
Materials
Tool Class
No. of Unit
5.0
No. of Unit
Material
Caution: Observe safety procedures at all times.
25.0
IMPORTANT: When using compressed air keep the nozzle at a safe distance from the fins to prevent any damage. If the fins are damaged, this may cause leakage or heating. Under dusty environment conditions, check it more often regardless of the maintenance interval.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 19 of 37
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 20 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.12 Swing drive unit oil level: check
Activity Number
(minutes)Duration
Maintenance Activity:
Activity
1
Pull out oil dipstick and wipe it with a clean cloth.
1.0
2
Insert the oil dipstick and pull it out again.
0.5
3
Check the oil level. If the level is in the center of C mark, the level is correct.
4
If the level is low, top up oil through oil fillet hole to the correct level.
3.0
5
If the level is high, - place a suitable sized container under drain valve, - open the protection cap of drain valve, - attach drain hose and drain the oil to the correct level, - disconnect the drain hose, and - close the protecting cap.
1.0
TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Visual Inspectionobserve safety procedures
7.50
IMPORTANT: Always clean around the oil level gauge before checking the oil level. Dirt in the oil damages the swing drive unit. It is very important that the oil level is always correct and that it is checked at operating temperature. Too little oil may lead to insufficient lubrication of the swing drive unit and cause costly damage. Too much oil may lead to oil foaming, and cause the swing drive to overheat.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 21 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.13 Travel reduction device oil: check (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Check machine is on firm level ground.
1.0
2
Rotate the track until ports (1 thru 3) are in their proper position.
0.5
3
Slightly loosen fill plug to allow pressurized air escape.
3.0
4
Remove oil level plug.
1.0
5
Check oil level. Oil should be near the bottom of the level plug opening.
0.50
6
Add oil through the fill plug opening, if necessary.
1.0
7
Clean and install oil and fill plugs.
3.0
8
Repeat this procedure on the other travel reduction device. TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Visual Inspectionobserve safety procedures
14.50
IMPORTANT: The gear oil is very hot after the operations. Shut all system down and allow them to cool. Before fully removing any motor case inspection port plug etc., loosen the plug slightly to allow pressurized air to escape.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 22 of 37
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Self- Check 2.3-1 TRUE OR FALSE: Direction: Tell whether the given statements about Daily Preventive Maintenance procedure are correct. Write T if the statement is true and F if the statement is false. Write your answer to a separate sheet.
_________1.
This means that drivers/operators should report any unusual noise immediately.
_________2.
Visual Inspection. observed.
Safety
procedures
should
be
_________3. In handling and releasing accumulator pressure, turn the ignition key to stop position. _________4. The engine oil level should be above the High mark. _________5. Start the engine and war it up until it reaches normal operating temperature. Then race the engine 2 or 3 times under no load. Watch the coolant temperature gauge for sign of overheating. _________6. In fuel system air bleeding, turn priming pump clockwise to unlock the plunger. _________7. If the hydraulic level is low, place a suitable sized contained under the hydraulic tank. _________8. If the hydraulic level is low, press breather to release the internal pressure at the tank. _________9. Compressed air will be used in cleaning radiator and oil cooler after detaching the clogging nets. _________10. In travel reduction device oil check, slightly loosen fill plug to allow pressurized air escape.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 24 of 37
ANSWER KEY 2.3-1 1. F 2. T 3. T 4. F 5. T 6. F 7. F 8. T 9. T 10.T
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 25 of 37
JOB SHEET 2.3-1 Title:
Performing Daily Preventive Maintenance Checklist
Performance Objective: Given the necessary tools, materials, supplies and equipment, you should be able to demonstrate correct procedures in preparing daily preventive maintenance Supplies / Materials: Daily Preventive Maintenance Checklist/Manual Equipment: Hydraulic Excavator, PPE and Tools Steps/Procedure: Performing Daily Preventive Maintenance
1.
Wear prescribe Personal Protective Equipment (PPE)
2.
Observe safety practice and proper housekeeping before and after performing the task.
3.
Prepare the needed tools, equipment and materials
4.
Perform the following procedures below basing from the daily checklist a. Accumulator Handlin and Releasing Pressure b. Before Starting Checkpoints c. Engine Oil Level Check/Top-up d. Engine Coolant Change e. Engine Coolant Check/Top-up f. Fuel Tank Drain g. Fuel System Air Bleeding h. Hydraulic System Releasing Pressure i. Hydraulic Oil Level Check j. Machine Set-up for Maintenance Primary Work k. Radiator, Oil Cooler and Condenser Fins (Cooling System): Check Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 26 of 37
l. Swing Drive Unit Oil Level: Check m. Travel Reduction Device Oil: Check 5.
After accomplishing each task. Put the corresponding information and remarks on the checklist.
6.
Observe housekeeping. Return each tools and materials in their proper place.
Assessment Method: Practical Demonstration Oral questioning
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Performance Criteria Checklist 2.3-1 CRITERIA Did you…. 1. Wear prescribe PPE 2. Observe safety practice and proper housekeeping before performing task. 3. Prepare the needed tools, equipment and materials 4. Perform Accumulator Handlin and Releasing Pressure 5. Perform Before Starting Checkpoints 6.
Perform Engine Oil Level Check/Top-up
7.
Perform Engine Coolant Change
8.
Perform Engine Coolant Check/Top-up
9.
Perform Fuel Tank Drain
10.
Perform Fuel System Air Bleeding
11.
Perform Hydraulic System Releasing Pressure
12. 13.
Perform Hydraulic Oil Level Check Perform Machine Set-up for Maintenance Primary Work Perform Radiator, Oil Cooler and Condenser Fins (Cooling System): Check Perform Swing Drive Unit Oil Level: Check
14. 15. 16. 17. 18.
YES
NO
Perform Travel Reduction Device Oil: Check Put the corresponding information and remarks on the checklist Observe housekeeping. Return each tools and materials in their proper place
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Information Sheet 2.3-1 Report Minor / Major Equipment Defects Of Hydraulic Excavator Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the procedures in preparing reports of Minor / Major equipment defects of Backhoe Loader Downtime and of an equipment maybe due to neglecting minor / major defects experienced during or before maintenance activity. In order to eliminate such situations, it is important to know the following defects and to report it immediately to appropriate personnel. Report Minor / Major Repair Equipment Logbook is used for recording of operational data such as odometer reading, kilometer / hour run, fuel consumption, parts and lubricant supplied or used, parts replaced, etc. Below is how to use and accomplish an equipment logbook 1. Fill out the front cover with the appropriate Property Number.
2. Read the
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
instructions at the
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3. Fill out other information (e.g. Equipment Type, Manufacturer /Model, Engine Make and Model, Fuel Tank Capacity, etc. )
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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4. Monitor the daily record of the equipment, such as the kilometer reading , hours operation, consumed fuel, etc.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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5. Record corresponding repairs (minor/major). Parts needed to be replaced will be requested using pre-repair inspection reports (work reqest) form to be accomplish by the user.
Work Request is a requirement for the issuance of Work Order (WO) and will notify the end-user for the possible scope of the repair and estimated time/costing of the work to be done. Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Below is how to use and accomplish a worl request 1. End user will fill out Section A or the form
2. Inspector will then review the cause of problem/fault and accomplish the succeding Section B
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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3. End user will then evaluate the findings and cost estimate of Section B. End user will the acknowledge and will affix their signature upon agreeing with the conditions written in Section B.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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JOB SHEET 2.3-2 Title:
Preparing Reports on Minor/Major Equipment Defects of Hydraulic Excavator
Performance Objective: Given the necessary tools, materials, supplies and equipment, you should be able to demonstrate correct procedures in preparing reports on minor/major equipment defects of hydraulic excavator Supplies / Materials: Equipment Logbook and Work Request (Pre-Repair Inspection Report) Equipment: Hydraulic Excavator, PPE and Tools Steps/Procedure: Preparing Equipment Logbook
7.
Wear prescribe Personal Protective Equipment (PPE)
8.
Observe safety practice and proper housekeeping before and after performing the task.
9.
Prepare the needed tools, equipment and materials
10.
Perform the following procedures below: n. Accomplish the Equipment Logbook (Label the Appropriate Property Number) o. Accomplish the Equipment Information Sheet in the Equipment Logbook p. Record the Daily Equipment Data. Such as Kilometer Run, Odometer Reading, Consumed Fuel, etc. q. Record corresponding repairs (minor/major). Parts needed to be replaced will be requested using the Pre-Repair Inspection Form. Preparing Work Request (Pre-Repair Inspection Form) a. End user will fill out Section A. b. Inspector will review accomplish Section B.
the
cause
of
problems/faults
and
c. End user will then evaluate the findings and cost estimate of Section B. End user will the acknowledge and will affix their Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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signature upon agreeing with the conditions written in Section B. 11.
Observe housekeeping. Return each tools and materials in their proper place.
Assessment Method: Practical Demonstration Oral questioning
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Performance Criteria Checklist 2.3-2 CRITERIA Did you…. 1. Wear prescribe PPE 2. Observe safety practice and proper housekeeping before performing task. 3. Prepare the needed tools, equipment and materials 4. Accomplish the Equipment Logbook (Label the Appropriate Property Number) 5. Accomplish the Equipment Information Sheet in the Equipment Logbook 6. Record the Daily Equipment Data. Such as Kilometer Run, Odometer Reading, Consumed Fuel, etc. 7. Properly Fill up Section A 8. Observe housekeeping. Return each tools and materials in their proper place.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
YES
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November 2019 Developed by: Erris S. Sanciangco
NO
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Conditions The students/trainees must be provided with the following: 1.WORK PLACE LOCATION 2.EQUIPMENT -
Computer/Laptop LCD
3.TOOLS, ACCCESSORIES AND SUPPLIES -
Whiteboard CD Tapes
4.TRAINING MATERIALS -
Learning Packages Ball pens Whiteboard Markers Manuals / Handouts Daily Preventive Maintenance Checklist Report Sheet / Log Sheet for Equipment
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Assessment Method: Written and/or oral questionings Direct observation/Practical demonstration Work record and documents
Learning Experiences Learning Outcome 3 PREPARE EQUIPMENT REPORTS Learning Activities
Special Instructions
1. Read Information Sheet 2.3-1 – Principles and Procedures of Daily Preventive Maintenance Checklist in accordance with manufacturer’s/company requirements
Read and understand the information sheet 2.3-1 on “Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist”
You must answer all the questions correctly before proceeding to the 2. Answer Self-Check 2.3-1 next activity. You can ask the Compare answers to Answer Key assistance of your trainer for further explanation regarding the 2.3-1 topic that you may not understand. 3. View the Power Point on Principles and Procedures of Daily Preventive Maintenance Checklist Answer the trainer’s question 4. Perform Task Sheet 2.3-1 – on Preparing Daily Preventive Maintenance
Listen and understand the power lecture or point presentation on “Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist”
Use appropriate tools, instruments, equipment, supplies and/or materials. Task sheet will help you practice your skills. The performance criteria checklist 2.3-1 on “Principles and Procedures
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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in Accomplishing Daily Preventive Maintenance Checklist” will guide and help you evaluate your work as you are practicing your skill. Evaluate your own work using the performance checklist. When you are ready, present your work to your trainer for final evaluation and training. Ask trainer if you can proceed to the next learning outcome.
5. Evaluate your output using Performance Criteria Checklist 2.3-1
6. Read Information Sheet 2.3-2 – Report Minor / Major Equipment Defects of Backhoe Loader
Read and understand the information sheet 2.3-2 on “Report Minor / Major Equipment Defects of Backhoe Loader”
7. Perform Task Sheet 2.3-2 – in Preparing Report Minor / Major Equipment Defects of Backhoe Loader
Use appropriate tools, instruments, equipment, supplies and/or materials. Task sheet will help you practice your skills. The performance criteria 2.3-2 on “Report Minor Equipment Defects of Loader” will guide and evaluate your work as practicing your skill.
checklist / Major Backhoe help you you are
Evaluate your own work using the performance checklist. When you are ready, present your work to your trainer for final evaluation and training. Ask trainer if you can proceed to the next Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
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November 2019 Developed by: Erris S. Sanciangco
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learning outcome.
8. Evaluate your output using Performance Criteria Checklist 2.3-2
Information Sheet 2.3-1 Principles and Procedures in Accomplishing Daily Preventive Maintenance Checklist Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the principles and use of Daily Preventive Maintenance Checklist 2. Identify the procedures in accomplishing the Daily Preventive Maintenance Checklist In LO 2 of Module Performing Basic Preventive-Maintenance for Backhoe Loader Operation you learned to perform basic preventive maintenance servicing (PMS). You learned to identify the OS parts/ standards according to manufacturer’s recommendation including the basic hand tools and equipment to be used in accordance with site requirements. In this module you will learn the principles and procedures in accomplishing the Daily Preventive Maintenance Checklist. Below is the step-by-step guide Maintenance of Hydraulic Excavator.
in
performing
the
Routine
LEGEND
Visual Inspectionobserve safety procedures Very Important! Regularly check these items. Caution: Observe safety procedures at all times Report any unusual noise immediately
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.1 Accumulator: Handling and releasing pressure
Activity Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools Date Developed:
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Materials
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(minutes)Duration
Activity Number 1 2 3 4
5 6 7 8
Lower the attachment completely to the ground. Keep all the attachments, such as hammer, closed. After turning off the engine, turn the ignition key to running position. Move the control lockout lever up to unlock the hydraulic system. To release the pressure in the control circuits and accumulator, move the operating levers and pedals forward/reward and left/right to their respective end positions. Turn the ignition key to stop position. Move the control lockout lever down to lock the hydraulic system securely. To release the pressure completely, loosen the hose connection slowly when you disconnect the accumulator. Step aside in this case as oil should spurt out.
TOTAL
Tool Class
No. of Unit
No. of Unit
Material
1.0 1.0 1.0 1.0
1.0 1.0 1.0
Caution: Observe safety procedures at all times.
Visual Inspectionobserve safety procedures
1.0 8.0
IMPORTANT: The accumulator is charged with highly pressured nitrogen gas. Handle it with care. Otherwise, it can cause serious accidentals or injuries.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader
Activity
3.2 Before starting: checkpoints (minutes)Duration
Activity Number
Maintenance Activity:
Tools
Tool Class
Materials No. of Unit
Material
Visual Inspection-observe safety procedures 1-pc
1
Check oil and water leak.
1.0
2
Check and retighten nuts and bolts.
3.0
3
Check electric wiring.
3.0
4
Check and supply coolant.
3.0
DO3 fluid
5
Check and supply engine oil.
3.0
Engine oil
6
Check and supply fuel.
3.0
7
Drain water and sediment of fuel tank.
3.0
8
Check and supply brake fluid.
3.0
9
Check steering wheel play.
1.0
10
Check and adjust brake pedal travel.
5.0
11
Check and adjust braking ability.
5.0
12
Check and adjust parking brake lever travel.
5.0
13
Check and adjust tire pressure.
5.0
14
Check dust indicator.
1.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Wrench Pliers, Electrical tape
No. of Unit
1-pc
Visual Inspectionobserve safety procedures
Pressure gauge
Date Developed:
1-pc
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.2 Before starting: checkpoints (minutes)Duration
Activity Number
Maintenance Activity:
Activity
15
Check lamps.
1.0
16
Check horn.
1.0
17
Check exhaust gas color.
1.0
18
Check instruments.
1.0
19
Check previous day’s defects.
1.0
20
Check door lock.
3.0
21 22
Check wiper, window washer and defroster. Inspect float position of water separator. TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Visual Inspectionobserve safety procedures
Logbook
2.0
Visual Inspectionobserve safety procedures
2.0 56.0
Date Developed:
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November 2019 Developed by: Erris S. Sanciangco
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.3 Engine oil level: Check/top-up (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Turn on the engine until it reaches operating temperature.
3.0
2
Turn off engine. Wait for a few minutes for the oil to drain back into the oil pan.
5.0
3
Pull out the dipstick and wipe it clean cloth.
0.5
4
Inspect the dipstick and pull it out again. It should be between the High and Low mark. If the oil is below the Low mark, remove the oil filler cap and pour recommended oil.
2.0
5
Recheck oil level with dipstick.
0.5
TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures Visual Inspectionobserve safety procedures
Screw driver
1-pc
SAE 30
1 liter
Visual Inspectionobserve safety procedures
11.0
Date Developed:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.4 Engine coolant: Change
1
2
3 4
5
Activity
Open the heater water cock. Manual air conditioning: move the temperature control lever to maximum hot position. Automatic air conditioning: turn the ignition switch On and move the temperature control lever to the maximum hot position.
Open the radiator cap and drain valve Open the drain plug on the engine block for the diesel engines. Flush the cooling system by running fresh water through the radiator. Securely close the drain valve (and drain plug for diesel engines). Fill the radiator with the proper mixture of coolant and water. Fill the reservoir tank up to the maximum level. The install the radiator cap.
(minutes)Duration
Activity Number
NOTE: Wait until the engine and radiator cool down. Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Caution: Observe safety procedures at all times. 2.5
2.5
5.0
Monkey wrench
1-pc
5.0
Pressurized water hose
1 assy
Drain pan
1-pc
1.0
10.0
Visual Inspectionobserve safety procedures
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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for Heavy Equipment Operation Backhoe Loader 3.4 Engine coolant: Change
Activity Number
(minutes)Duration
Maintenance Activity:
Activity
6
Start the engine and war it up until it reaches normal operating temperature. Then race the engine 2 or 3 times under no load. Watch the coolant temperature gauge for sign of overheating.
7
Stop the engine after it completely cools down. Refill the radiator up to the filler opening. Fill the reservoir tank up to this maximum level.
15.0
8
Check the drain valve (and drain plug for diesel engines) for any sign of leaks.
1.0
TOTAL
62.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
20.0
Date Developed:
Visual Inspectionobserve safety procedures
Document No.:
November 2019 Developed by: Erris S. Sanciangco
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.5 Engine coolant level: Check/top-up (minutes)Duration
Activity Number
Maintenance Activity:
Activity
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
1-pc
1
Wait until the engine and radiator cool down.
3.0
2
Open the radiator cap and drain valve.
1.0
Drain pan
3
Flush the cooling system by running the fresh water thru the radiator.
3.0
Soft water
4
Securely close the drain valve.
0.5
5
Fill the radiator with the proper mixture of coolant and water. Fill the reservoir tank to level. Tightly close the radiator tank.
6
Start the engine and warm it up until it reaches normal temperature.
3.0
7
Check the drain valve for possible leaks.
0.5
TOTAL
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
3.0
Soft water 70% Anti-freeze solution 30% Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
14.0
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.6 Fuel tank: drain
(minutes)Duration
Activity Number
NOTE: If the equipment runs with fuel of low quality, the fuel tank needs to be drained.
Activity
1
Place a suitable sized container under drain hose.
1.0
2
Open the drain valve cap at the bottom of the tank.
2.0
3
Open the filler cap.
0.5
4
Connect the drain hose and drain off any sediment.
4.0
5
Disconnect the drain hose and install the valve cap again.
2.0
6
Close the filler cap
0.5 TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Drain pan
1-pc
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
10.0
IMPORTANT: Take care of filter/ oil/ liquids in an environmentally safe way.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
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Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.7 Fuel system: Air bleeding
Activity Number
(minutes)Duration
NOTE: Air must be bled out the fuel injection system whenever the machine runs out of fuel while the engine is running.
Activity
1
Turn priming pump counterclockwise to unlock the plunger.
1.0
2
Push priming pump until a heavy resistance can be felt in the priming pump.
3.0
Push priming pump fully and turn it clockwise to lock the plunger.
1.0
3
4
Start the engine and let it run idle for 3 minutes.
3.0
5
If the engine is difficult to start, repeat (1) to (3).
5.0
6
Check for any leaks.
1.0 TOTAL
Tools
Tool Class
Materials No. of Unit
Material
No. of Unit
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
14.0
IMPORTANT: Do not attempt to start the engine under any circumstances until the air in the system has been bled out completely otherwise the injection pump may be seriously damaged.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.8 Hydraulic system: Releasing pressure (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Place attachment on the ground and shut down engine.
5.0
2
After engine is shut down, turn ignition key to running position (Do not start engine).
0.25
3
4
Keep the control lockout lever up (unlocked position) and move all control levers and pedals to release main system pressure from all lines. Turn ignition key to off position. Remove the key and tag the machine to indicate that the unit is under service.
Tool Class
1.0
1.0
5
Lower the control lockout lever (locked position).
1.0
6
Press the pressure relief valve located on the hydraulic tank breather valve to release tank pressure.
1.0
TOTAL
Tools
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
9.25
IMPORTANT: Release the internal pressure of the tank and hydraulic lines before removing any components of hydraulic system. Otherwise leakage may cause high pressure to build up in the hydraulic circuit. If the work cannot be completed within a short time after the system was released, the system pressure must be released again.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.9 Hydraulic oil level: check (minutes)Duration
Activity Number
NOTE: When refilling the oil, use the same oil as the system is filled with.
Activity
1
Park the machine in service position.
1.0
2
Move the control lockout lever down to lock the system securely and stop the engine.
1.0
3
4
Open the side door on the right side of the machine and check the oil level in the sight gauge. If the level is in the center of the gauge, the level is correct. If the level is low, - press breather to release the internal pressure at the tank - unscrew the bolts - remove the cover and spring - top up the oil. Top up the oil efficiency press air breather again - check the level.
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
2.0
0.5 2.0 2.0 5.0
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
1.0 5
If the level is normal, clean the dismantled parts and install.
6
If the level is high, - place a suitable sized contained under the hydraulic tank - removed the protecting cap and attach drain hose which is the same hose as that used for draining engine oil - drain the oil into a container. TOTAL Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
0.25
Drain pan
1-pc
1.0 1.0
5.0 21.75 Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.10 Machine set-up for maintenance: Primary work (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Park on firm, level ground
2.0
2
After engine is shut down, turn ignition key to running position (Do not start engine).
0.25
3
4
Keep the control lockout lever up (unlocked position) and move all control levers and pedals to release main system pressure from all lines. Turn ignition key to off position. Remove the key and tag the machine to indicate that the unit is under service.
1.0
Set level on lock position.
0.5
6
Before starting maintenance work, hang up a tag on cap door or work lever.
1.0
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Tool Class
1.0
5
TOTAL
Tools
Materials No. of Unit
No. of Unit
Material
Caution: Observe safety procedures at all times. Visual Inspectionobserve safety procedures
9.75
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
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Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader Maintenance Activity:
3.11 Radiator, oil cooler and condenser Fins (cooling system): clean
Activity Number
(minutes)Duration
NOTE: Wear safety googles or a face mask. Do not use steam to clean the air conditioner condenser.
Activity
1
Remove any mud or dust attached to the radiator find and oil cooler fins with compressed air.
5.0
Pressurized air cleaner
1-pc
2
Clean radiator and oil cooler with compressed air after detaching the clogging nets.
5.0
Pressurized air cleaner
1-pc
3
Clean the gap between oil cooler and radiator with compressed air after opening engine hood.
5.0
Pressurized air cleaner
1-pc
4
Clean the radiator with compressed air after detaching the air conditioner.
5.0
Pressurized air cleaner
1-pc
5
Check the rubber hose for wear and cracks. If damaged, replace it. Check loose hose clamps. TOTAL
Tools
Materials
Tool Class
No. of Unit
5.0
No. of Unit
Material
Caution: Observe safety procedures at all times.
25.0
IMPORTANT: When using compressed air keep the nozzle at a safe distance from the fins to prevent any damage. If the fins are damaged, this may cause leakage or heating. Under dusty environment conditions, check it more often regardless of the maintenance interval.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
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Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 20 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.12 Swing drive unit oil level: check
Activity Number
(minutes)Duration
Maintenance Activity:
Activity
1
Pull out oil dipstick and wipe it with a clean cloth.
1.0
2
Insert the oil dipstick and pull it out again.
0.5
3
Check the oil level. If the level is in the center of C mark, the level is correct.
4
If the level is low, top up oil through oil fillet hole to the correct level.
3.0
5
If the level is high, - place a suitable sized container under drain valve, - open the protection cap of drain valve, - attach drain hose and drain the oil to the correct level, - disconnect the drain hose, and - close the protecting cap.
1.0
TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Visual Inspectionobserve safety procedures
7.50
IMPORTANT: Always clean around the oil level gauge before checking the oil level. Dirt in the oil damages the swing drive unit. It is very important that the oil level is always correct and that it is checked at operating temperature. Too little oil may lead to insufficient lubrication of the swing drive unit and cause costly damage. Too much oil may lead to oil foaming, and cause the swing drive to overheat.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 21 of 37
Routine Maintenance to be performed by Excavator Operator who had completed the TESDA Core Competencies Standards for Heavy Equipment Operation Backhoe Loader 3.13 Travel reduction device oil: check (minutes)Duration
Activity Number
Maintenance Activity:
Activity
1
Check machine is on firm level ground.
1.0
2
Rotate the track until ports (1 thru 3) are in their proper position.
0.5
3
Slightly loosen fill plug to allow pressurized air escape.
3.0
4
Remove oil level plug.
1.0
5
Check oil level. Oil should be near the bottom of the level plug opening.
0.50
6
Add oil through the fill plug opening, if necessary.
1.0
7
Clean and install oil and fill plugs.
3.0
8
Repeat this procedure on the other travel reduction device. TOTAL
Tools
Tool Class
Materials No. of Unit
No. of Unit
Material
Visual Inspectionobserve safety procedures
14.50
IMPORTANT: The gear oil is very hot after the operations. Shut all system down and allow them to cool. Before fully removing any motor case inspection port plug etc., loosen the plug slightly to allow pressurized air to escape.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 22 of 37
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 23 of 37
Self- Check 2.3-1 TRUE OR FALSE: Direction: Tell whether the given statements about Daily Preventive Maintenance procedure are correct. Write T if the statement is true and F if the statement is false. Write your answer to a separate sheet.
_________1.
This means that drivers/operators should report any unusual noise immediately.
_________2.
Visual Inspection. observed.
Safety
procedures
should
be
_________3. In handling and releasing accumulator pressure, turn the ignition key to stop position. _________4. The engine oil level should be above the High mark. _________5. Start the engine and war it up until it reaches normal operating temperature. Then race the engine 2 or 3 times under no load. Watch the coolant temperature gauge for sign of overheating. _________6. In fuel system air bleeding, turn priming pump clockwise to unlock the plunger. _________7. If the hydraulic level is low, place a suitable sized contained under the hydraulic tank. _________8. If the hydraulic level is low, press breather to release the internal pressure at the tank. _________9. Compressed air will be used in cleaning radiator and oil cooler after detaching the clogging nets. _________10. In travel reduction device oil check, slightly loosen fill plug to allow pressurized air escape.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 24 of 37
ANSWER KEY 2.3-1 1. F 2. T 3. T 4. F 5. T 6. F 7. F 8. T 9. T 10.T
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 25 of 37
JOB SHEET 2.3-1 Title:
Performing Daily Preventive Maintenance Checklist
Performance Objective: Given the necessary tools, materials, supplies and equipment, you should be able to demonstrate correct procedures in preparing daily preventive maintenance Supplies / Materials: Daily Preventive Maintenance Checklist/Manual Equipment: Hydraulic Excavator, PPE and Tools Steps/Procedure: Performing Daily Preventive Maintenance
1.
Wear prescribe Personal Protective Equipment (PPE)
2.
Observe safety practice and proper housekeeping before and after performing the task.
3.
Prepare the needed tools, equipment and materials
4.
Perform the following procedures below basing from the daily checklist a. Accumulator Handlin and Releasing Pressure b. Before Starting Checkpoints c. Engine Oil Level Check/Top-up d. Engine Coolant Change e. Engine Coolant Check/Top-up f. Fuel Tank Drain g. Fuel System Air Bleeding h. Hydraulic System Releasing Pressure i. Hydraulic Oil Level Check j. Machine Set-up for Maintenance Primary Work k. Radiator, Oil Cooler and Condenser Fins (Cooling System): Check Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 26 of 37
l. Swing Drive Unit Oil Level: Check m. Travel Reduction Device Oil: Check 5.
After accomplishing each task. Put the corresponding information and remarks on the checklist.
6.
Observe housekeeping. Return each tools and materials in their proper place.
Assessment Method: Practical Demonstration Oral questioning
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 27 of 37
Performance Criteria Checklist 2.3-1 CRITERIA Did you…. 1. Wear prescribe PPE 2. Observe safety practice and proper housekeeping before performing task. 3. Prepare the needed tools, equipment and materials 4. Perform Accumulator Handlin and Releasing Pressure 5. Perform Before Starting Checkpoints 6.
Perform Engine Oil Level Check/Top-up
7.
Perform Engine Coolant Change
8.
Perform Engine Coolant Check/Top-up
9.
Perform Fuel Tank Drain
10.
Perform Fuel System Air Bleeding
11.
Perform Hydraulic System Releasing Pressure
12. 13.
Perform Hydraulic Oil Level Check Perform Machine Set-up for Maintenance Primary Work Perform Radiator, Oil Cooler and Condenser Fins (Cooling System): Check Perform Swing Drive Unit Oil Level: Check
14. 15. 16. 17. 18.
YES
NO
Perform Travel Reduction Device Oil: Check Put the corresponding information and remarks on the checklist Observe housekeeping. Return each tools and materials in their proper place
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 28 of 37
Information Sheet 2.3-1 Report Minor / Major Equipment Defects Of Hydraulic Excavator Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to: 1. Identify the procedures in preparing reports of Minor / Major equipment defects of Backhoe Loader Downtime and of an equipment maybe due to neglecting minor / major defects experienced during or before maintenance activity. In order to eliminate such situations, it is important to know the following defects and to report it immediately to appropriate personnel. Report Minor / Major Repair Equipment Logbook is used for recording of operational data such as odometer reading, kilometer / hour run, fuel consumption, parts and lubricant supplied or used, parts replaced, etc. Below is how to use and accomplish an equipment logbook 1. Fill out the front cover with the appropriate Property Number.
2. Read the
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
instructions at the
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 29 of 37
3. Fill out other information (e.g. Equipment Type, Manufacturer /Model, Engine Make and Model, Fuel Tank Capacity, etc. )
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 30 of 37
4. Monitor the daily record of the equipment, such as the kilometer reading , hours operation, consumed fuel, etc.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 31 of 37
5. Record corresponding repairs (minor/major). Parts needed to be replaced will be requested using pre-repair inspection reports (work reqest) form to be accomplish by the user.
Work Request is a requirement for the issuance of Work Order (WO) and will notify the end-user for the possible scope of the repair and estimated time/costing of the work to be done. Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 32 of 37
Below is how to use and accomplish a worl request 1. End user will fill out Section A or the form
2. Inspector will then review the cause of problem/fault and accomplish the succeding Section B
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 33 of 37
3. End user will then evaluate the findings and cost estimate of Section B. End user will the acknowledge and will affix their signature upon agreeing with the conditions written in Section B.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 34 of 37
JOB SHEET 2.3-2 Title:
Preparing Reports on Minor/Major Equipment Defects of Hydraulic Excavator
Performance Objective: Given the necessary tools, materials, supplies and equipment, you should be able to demonstrate correct procedures in preparing reports on minor/major equipment defects of hydraulic excavator Supplies / Materials: Equipment Logbook and Work Request (Pre-Repair Inspection Report) Equipment: Hydraulic Excavator, PPE and Tools Steps/Procedure: Preparing Equipment Logbook
7.
Wear prescribe Personal Protective Equipment (PPE)
8.
Observe safety practice and proper housekeeping before and after performing the task.
9.
Prepare the needed tools, equipment and materials
10.
Perform the following procedures below: n. Accomplish the Equipment Logbook (Label the Appropriate Property Number) o. Accomplish the Equipment Information Sheet in the Equipment Logbook p. Record the Daily Equipment Data. Such as Kilometer Run, Odometer Reading, Consumed Fuel, etc. q. Record corresponding repairs (minor/major). Parts needed to be replaced will be requested using the Pre-Repair Inspection Form. Preparing Work Request (Pre-Repair Inspection Form) a. End user will fill out Section A. b. Inspector will review accomplish Section B.
the
cause
of
problems/faults
and
c. End user will then evaluate the findings and cost estimate of Section B. End user will the acknowledge and will affix their Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 35 of 37
signature upon agreeing with the conditions written in Section B. 11.
Observe housekeeping. Return each tools and materials in their proper place.
Assessment Method: Practical Demonstration Oral questioning
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
Document No.:
November 2019 Developed by: Erris S. Sanciangco
BLO0001 Issued by:
Page 36 of 37
Performance Criteria Checklist 2.3-2 CRITERIA Did you…. 1. Wear prescribe PPE 2. Observe safety practice and proper housekeeping before performing task. 3. Prepare the needed tools, equipment and materials 4. Accomplish the Equipment Logbook (Label the Appropriate Property Number) 5. Accomplish the Equipment Information Sheet in the Equipment Logbook 6. Record the Daily Equipment Data. Such as Kilometer Run, Odometer Reading, Consumed Fuel, etc. 7. Properly Fill up Section A 8. Observe housekeeping. Return each tools and materials in their proper place.
Heavy Equipment Operation (Backhoe Loader) NC II Perform Basic Preventive Maintenance for Backhoe Loader Operation
Date Developed:
YES
Document No.:
November 2019 Developed by: Erris S. Sanciangco
NO
BLO0001 Issued by:
Page 37 of 37
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