HEAVY EQUIPMENT SERVICES MÉCANIQUE DE MACHINERIE LOURDE POST-SECONDARY NIVEAU POSTSECONDAIRE

Transcription

1 TEST PROJECT 5 OF 6 PROJET D ÉPREUVE 5 DE 6 HEAVY EQUIPMENT SERVICES MÉCANIQUE DE MACHINERIE LOURDE POST-SECONDARY NIVEAU POSTSECONDAIRE

2 Electrical System (5 of 6) TASK Competitor number Judge s name Start time Finish time Time limit: 2 hours Equipment: John Deere machine Number of tasks: 2 Competition Overview Task 1: Diagnose faulty electrical charging system. Value 50 % Task 2: Evaluate condition of batteries. Value 50 % General Instructions: The judge has all the materials you will need. If you are unsure about any procedure, you may ask your judge for clarification. o Marks may be deducted if the judge decides you should know the procedure. Before you start, you must go through the following Hazard Assessment with your judge so that you will be able to work safely. Page 9

3 Hazard Assessment: This Hazard Assessment is to discuss the following 6 hazards and the counteractive measures you must take. Hazard 1: You might slip while getting into and out of the cab. Use three points of contact at all times. Always face the cab. Hazard 2: Shorting electrical connections might damage electrical components. Do not short electrical components together. Hazard 3: Sparks or ignition sources may cause the battery to explode. Do not generate sparks or bring ignition sources near the batteries. Wear a face shield. Hazard 4: Battery electrolyte (sulfuric acid) is corrosive. Wear a face shield, gloves and an apron when handling electrolyte. Hazard 5: Moving components on the engine can catch loose clothing and hurt you. Keep hands clear of moving components such as fan, pulleys, and belts. Hazard 6: Power steering system can create extreme forces that could crush you. Stay clear and keep others clear of pinch zones near the steering tires and steering linkages. If you do not quite understand or are unsure about the hazards, please ask your judge for assistance. No marks will be deducted for asking about hazards. I have read this hazard assessment and the judge has explained it to me. I understand the hazards and I will take precautions to avoid them. Competitor s name Judge s name Date Page 10

4 Number of marks possible: 18.2 Skills evaluated a. Use of safety equipment & safe and clean workspace b. Use and interpretation of service manuals & schematic diagrams c. Logical order of repair d. Proper use of tools e. Precise adjustment of components f. Accurate measurements g. Superior Workmanship h. Identification of faults, codes, or components If you cannot proceed with a task, ask your judge for assistance. Page 11

5 Task 1 of 2: Diagnose faulty electrical charging system. Value 50% 1. Follow the manufacturer s procedures to safely, appropriately, and accurately: Diagnose faulty electrical charging system. 2. In point form; briefly record your findings and any adjustments or components that were out of specifications. 3. In point form; briefly explain what the repair procedure is. If you cannot proceed with a task, ask your judge for assistance. Page 12

6 Task 2 of 2 : Evaluate condition of batteries Value 50% 1. Visual Inspection. Follow Step #1 of the Four-Step Battery-Check Sheet Look at the battery and record your observations below. (For example, is the battery case cracked, bulged, or broken? Are the battery terminals corroded? What is the colour and level of the electrolyte solution? Etc.) Cracks in Battery Case Bulge In the Battery Case Corroded Terminals Electrolyte Level low Yes No Page 13

7 2. Percentage-of-Charge Test. Follow Step #2 of the Four-Step Battery-Check Sheet. (Use the table below to record your findings.) a. Use a hydrometer (rinse in clear water after every cell). b. For each reading, calculate the temperature-compensated reading. Use the following formula: To every 10 o C more than 27 o C, add specific gravity (SG). To every 10 o C less than 27 o C, subtract specific gravity (SG). c. If the temperature is not provided on the hydrometer, use 17 degrees Celsius as the reference temperature. d. Use a refractometer to compare the hydrometer reading of cell #6. Cell # Initial Reading Battery 1 Battery 2 Temperature-Compensated Reading Battery 1 Battery Refractometer Reading Temperature-Compensated Reading Not Required Required Page 14

8 3. Load-test the batteries. Follow Step #3 of the Four-Step Battery-Check Sheet. NOTE:If the Cold-Cranking Amperage (CCA) is not found on your battery, use 525 CCA. Battery voltages best before test: Battery ratings: Current draw for testing: Battery voltages after test: Battery voltages during test: Battery conditions: (Circle your answer) Pass/Fail Pass/Fail 4. Bounce-back test. Follow Step #4 of the Four-Step Battery - Check Sheet. Record your results: 5. Battery Case Leakage Test Using a digital voltmeter connect the red test lead of the meter to the POS + terminal of the batteries. Use the black test lead and search for voltage readings around the top of the battery case, particularly around the filler caps and vents. Record your largest voltage readings: Explain where you found the highest battery case leakage reading: If you cannot proceed with a task, ask your judge for assistance. Page 15

9 Congratulations! You have completed the required tasks. Once you have completed this topic you must clean up your workstation and return any tools/materials. Use the space below for comments. Return this competition form to your judge for evaluation. Page 16