CBLM Motor2
CBLM Motor2
CBLM Motor2
SECTOR:
AUTOMOTIVE AND LAND TRANSPORT SECTOR
QUALIFICATION:
MOTORCYCLE AND SMALL ENGINE SERVICING
UNIT OF COMPETENCY:
SERVICE COOLING SYSTEM
MODULE TITLE:
SERVICING COOLING SYSTEM
PREPARED BY:
List of Competencies
Overhaul Overhauling
Motorcycle/Small Motorcycle/Small ALT723347
Engine Engine
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HOW TO USE THIS COMPETENCY- BASED LEARNING
MATERIALS
Welcome!
The unit of competency, "_Service Cooling System_________________________
(Unit of Competency)", is one of the competencies of Motorcycle and Small
Engine Servicing______________________________ (Qualification), a course
which comprises the knowledge, skills and attitudes required for a TVET
trainer to possess. The module, _______________________ (Module Title),
contains training materials and activities related to identifying learners
requirements, preparing session plan, preparing basic instructional
materials and organizing learning and teaching activities for you to
complete. In this module, you are required to go through a series of learning
activities in order to complete each learning outcome. In each learning
outcome are Information Sheets, Self-Checks, Task Sheets and Job Sheets.
Follow and perform the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator.
Remember to:
Perform the Task Sheets and Job Sheets until you are confident that your
outputs conform to the Performance Criteria Checklist that follows the
sheets.
Submit outputs of the Task Sheets and Job Sheets to your facilitator for
evaluation and recording in the Accomplishment Chart. Outputs shall
serve as your portfolio during the Institutional Competency Evaluation.
When you feel confident that you have had sufficient practice, ask your
trainer to evaluate you. The results of your assessment will be recorded in
your Progress Chart and Accomplishment Chart. You must pass the
Institutional Competency Evaluation for this competency before moving to
another competency. A Certificate of Achievement will be awarded to you
after passing the evaluation. You need to complete this module before you
can perform the module on ____________________________(Next Module Title)
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MODULE CONTENT
LEARNING OUTCOMES:
At the end of this module you MUST be able to:
Inspect, check and service cooling system components.
Diagnose faults from symptoms and decide preferred action
Repair cooling system components
ASSESSMENT CRITERIA:
: REPAIR COOLING SYSTEM COMPONENTS
ASSESSMENT CRITERIA:
CONTENTS:
CONDITIONS:
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3. Socket wrench
4. Pliers
5. Screw drivers
6. Hammer
7. Parts replacements
8. Manufacturers Specification manual
9. Shop uniform
10. Learning module
METHODOLOGIES:
ASSESSMENT METHODS:
1. Observation
2. Demonstration
3. Interview/ Questioning
4. Written test
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LEARNING OUTCOME NO.3
Contents:
Assessment Criteria
Assessment Method:
Revision # 01
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Learning Experiences
Learning Outcome
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Information Sheet 12.3-1
Safety Precautions in replacing and Removing Component of
Cooling System Based on Manufactures Specification
Learning Objectives:
After reading this information sheet, you must be able to:
1. understand the safety precautions in removing and replacing
cooling system components without causing damage to any of the other
components;
2. explain the steps in removing component parts of cooling system;
3. follow the manufactures specification manual in replacing parts of
cooling system.
(Introductory Paragraph
This information sheet covers the safety standards and proper steps in
replacing parts of cooling system with reference to the manufacturers
service manual. Proper maintenance service procedure in safe efficient
operation of all motor vehicles, as well as to the safety of the person
performing the work.
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SAFETY PROCEDURE WHILE WORKING THE COOLING
SYSTEM OF A VEHICLE
Proper maintenance and service procedures are vital to the safe,
efficient operation of all motor vehicles, as well as to the safety of the person
performing the workyou.
Whenever you are working on your vehicle, we recommend that you
follow these important safety rules:
1. Do have a first-aid kit handy.
2. Do be careful when working around hot or sharp objects.
3. Do follow the manufacturer's instructions for all products.
4. Do use safety stands under the frame or drive-on ramps if you
must raise your vehicle.
5. Don't run the engine without proper ventilation.
6. Don't smoke when working around the engine.
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SAFETY CHECK BEFORE DOING REPAIR AND REPLACEMENT OF PARTS OF
COOLING SYSTEM OF A VEHICLE
1. Never try to assess the serviceability of a coolant hose while the engine is
hot. Let it to cool down so that you can handle the hoses comfortably and
safely.
2. Always ensure the engine is turned 'off' before attempting to check the
radiator hoses.
3. Always make sure that you wear the appropriate personal protection
equipment before starting the job. It is very easy to hurt yourself even when
the most exhaustive protection measures are taken.
4. Always make sure that your work area/environment is as safe as you can
make it of not use damaged, broken or worn out workshop equipment.
5. Always follow any manufacturer's personal safety instructions to prevent
damage the vehicle you are servicing.
6. Make sure that you understand and observe all legislative and personal
safety procedures when carrying out the following tasks. If you are unsure of
what these are, ask your supervisor.
RADIATOR MAINTENANCE
1. Most all water cooled engines have a radiator, thermostat, fan, pump, and the
connecting hoses and pipes. The fans are usually controlled by a heat activated,
thermostatic switch located in the radiator. For the most part they are trouble free,
but there are a few things you need to know.
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2. Always run antifreeze, in a 50/50
mix, in the radiator. If you use water
and forget to put antifreeze in and
things freeze... it could crack your
engine block/cylinder and ruin your
engine. Always use a motorcycle type
antifreeze or a car type without
silicates. Some car types contain
silicates that can accelerate wear on
your water pump. This probably doesn't
matter for dirt bikes because they just don't put on that many miles, but in a street
bike it's important. Use an antifreeze designed for an aluminum engine without
silicates. There are several brands on the market, just read the label. Always use
distilled water, if possible. This cuts down on the buildup of mineral salts that can
coat the inside of the radiator, cutting down it's efficiency. It's also a good idea to
replace the hoses every couple of years they tell me but I don't think very many
people do. It's still a good idea. Same with the antifreeze fluid too.
3.If things start running hot and the fluid level is ok, check the thermostat. You
can check it by suspending the thermostat in a pan of water with a
thermometer.Then heat the water and see if it opens at the temperature that's
marked on the thermostat. If it does, check to see if the pump is pumping. Take the
radiator cap off and look down the fill tube. Not the overflow (coolant reservoir) tank
cap, but the pressure cap on the radiator. Do this with the thermostat out and you
should be able to see the fluid flow through the radiator. You could do it with the
thermostat in but you have to let everything heat up so the thermostat will open.
Could be fun! If there is flow, then the pump is working, check for a plugged
radiator. Some you can fix and others you have to replace and they're not cheap.
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4.If the temperature goes up just when you are idling at a stop light and the fluidL
level l is OK, check it see if the fan works. Sometimes you can just ground the
wire going to the fan thermostat switch, or pull the wires at the fan and connect
them directly to the battery. If the fan works, replace the sending unit.
You can run without a thermostat but it's not a good idea because the thermostat
controls the flow of water from the radiator to the engine. Some old line mechanics
theorize that if the flow is too fast, the water doesn't stay in the radiator long
enough to cool off so your engine could end up running too hot. Others disagree
and feel the engine will run too cold and never reach operating temperature. It may
depend on how efficient the system is to begin with. Also, when starting from cold,
it would keep the engine too cold, as the engine would have to heat up all the
coolant in the radiator as well as the engine coolant. Take your pick, but all agree
you need a thermostat to keep the engine temperature right.
Coolant Reservoir
Most Cooling Systems have a Coolant Reservoir Tank, also called a Recovery or
Overflow Tank. This tank catches coolant that overflows from the radiator when it
is hot then, as the engine cools, the coolant is sucked back into the radiator.
Radiators operate under pressure. The Radiator Cap holds the pressure in until it
reaches whatever pressure the cap is set for, usually ten to twenty pounds. When
the engine gets hot from running, the internal pressure of the Radiator goes over
the pressure of the Radiator Cap. The cap then releases that pressure into the
When the radiator is full of Anti-Freeze the Anti-Freeze is vented into the overflow
tank. When the engine is turned off and everything cools down the Anti-Freeze is
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sucked back into the Radiator. The Over Flow Tank
should have just a bit of Anti-Freeze in it when cold.
There is usually a line on the tank. Keep the coolant
level at this line. That way it has room for the over
flow when hot but still has all the Anti-freeze the
Radiator needs when it is cold.
Radiator Parts Engines run usually best with a 190 degree thermostat. Most bike
thermostats only come in one temperature... the one they give you! I just mention
this because some people think that running a cooler thermostat helps the engine
cool better, but it doesn't really matter. Combustion runs a lot hotter than that
water. 10-15 degrees doesn't mean a thing to that engine, but where I live it's
cold... I really like a nice HOT heater! But, as bikes don't have heaters (I guess they
could though.) this whole paragraph doesn't really matter! Anyway...
If you start your engine and water starts coming out the radiator cap you might
have a blown head gasket or a cracked head. Somehow combustion pressure is
getting into the cooling system. Of course, not always... people tell me all the time
I've got a cracked head, but I ride an air cooled BMW, and I've checked. Its head is
not cracked... I wonder what they mean?
Radiator
You may have more that one radiator. Many dirt bikes have
two.
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One Radiator Two Radiator
Cylinder Coolant Passages Coolant Fouled Spark Plug Always run the engine
easy till the engine and coolant warm up. If you push things hard with a cold
engine you could get what some call "Cold Seizure". Some think the piston expands
faster than the cool cylinder, others think the problem is poor lubrication. Doesn't
make much difference what you think causes it if you end up walking, so warm the
engine up before you push it OK? Good idea even with an air cooled engine.
If your head gasket is leaking a bit it can foul out your spark plug.
Heads and Cylinders are cooled with water through passages in the cylinder.
Sometimes they have O-Rings for head gaskets.
Most Fans are electric and a sensor on the radiator tells the Fan when to turn on or
off. Some Fans are mounted on an engine driven shaft and can break like this one
from a CX500 Honda.
Do not get the anti-freeze on painted surfaces. It could harm the paint. Also
remember that anti-freeze is very poisonous. Do not leave pans of it sitting around
where unauthorized personal (Like pet dogs) could get into it.
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Self- Check 12.3-1
___________1. To check the radiator hose, we should assure that the ignition switch
is turned off.
__________2. To prevent damage we should always observe personal safety tips;
___________3. It is necessary to check regularly the coolant level and radiator hose
for leaks ?
___________4. An example of hand protection equipment is earplugs.
_________5. In the product design process, the main purpose of visualization
is to present detailed drawing from which the client ca select.
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ANSWER KEY (code no.)
1. T
2. T
3. T
4. F
5. T
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TASK SHEET (code no.)
Title:
Supplies/Materials :
Equipment :
Steps/Procedure:
1.
2.
3.
4.
Assessment Method:
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INFORMATION SHEET 12.3-2
Manufacturers Included
Arctic Cat, Harley-Davidson, Honda, Kawasaki, KTM, KYMCO, Polaris, Suzuki,
Victory and Yamaha
Specifications Included
Here are just a few of the specifications available to you:
Capacities Coolant
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Capacities Engine Oil Classification
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Electrical Ignition Coil Peak Voltage
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Engine Clutch Steel Disc Warp
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Engine Piston Ring End Gap 2nd
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Fuel Carburetor Float Height
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TASK SHEET 12.3-2
Title: Safety precautions in replacing and removing component of
cooling system following manufacturers specifications
Equipment : Radiator
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Performance Criteria Checklist 12.3-2
CRITERIA
YES NO
Did you.
1.Follow the safety procedure in removing and replacing
parts of cooling system based from manufacturers
specification;
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Evidence Plan
Questioning
Portfolio
Written
The evidence must show that the trainee
Cylinder head cooling fins checked for dirt and
cracks
Blower fan blade checked for cracks and dents
Blower fan mounting bolts checked for tightness
Mixing ratio of coolant solution and water
corrected
Radiator cap valve release pressure checked
Radiator hose checked for cracks / leaks
Radiator clamp checked for looseness
Radiator coolant checked for air
Radiator assembly tightness checked by using
radiator tester
Radiator clamp checked for cracks and fins for
damage
Reservoir tank checked for correct coolant level
and leakage
Overflow hose of reservoir tank checked for
cracks
Check water temperature gauge operation and
function
Auxiliary fan motor operation checked
Auxiliary fan motor relay switch checked
Mechanical seal checked for damage
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Mechanical seal ring and O-ring checked
Bearing and seal condition checked
Water impeller checked for damage
Thermostat pellet inspected for cracks
Thermostat valve opening temperature checked
Function check on sending unit conducted
Radiator shroud unit checked / re-tightened
Radiator shroud checked for crack and dirt
Radiator shroud mounting bolts are checked and re-
tightened
Coolant concentration checked according to specified
ratio
Fault and defective component identified as per
symptoms
No damage done on other components during
diagnosis
Test equipment used are set as per required
specification in the manufacturers manual
Findings and report are forwarded to supervisor and
client is informed
Cooling system repaired without causing damage to
any of the other components
Repairs carried out according to manufacturers
current specification
Appropriate guards and cover are used
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TABLE OF SPECIFICATION
Objectives/Content Percentage
Knowledge Comprehension Application
area/Topics of test
Safety precautions
in replacing and
removing 10% 10% 40% 60%
component of
cooling system
Use of
manufacturers
specification manual 15% 15% 10% 40%
TOTAL 100%
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ITEM ANALYSIS
Objectives/Content # of test
Knowledge Comprehension Application
area/Topics item
Safety precautions
in replacing and
removing 2 2 8 12
component of
cooling system
Use of
manufacturers
specification manual 2 2 4 8
TOTAL 20 Items
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Written Test
Name:_Caesar Madridano Date: 11-05-15 Score:___________
Multiple Choice: Using bank sheet of paper write the letter of the best
answer
1.It allows the radiator fan to turn with the belt at low engine speed.
a. radiator
b. fan clutch
c. front whe
2. If the coolant temperature falls below the normal temperature, What
will happen to the thermostat?
a. block the coolant flow
b. coolant will circulate
c.the temperature raise high
3. How do you diagnose a faulty radiator?
a. perform pressure testing
b. perform chemical testing
c.all of the above
4. It is an on/off type switch with a fixed temperature settings
a. sensor
b. thermostat
c.radiator hose
5. what should be the recommended design of a cooling system?
a. pressurized
b. with exhaust vent
c.none of the above
6. How to check the temperature indicator gauge?
a. temperature is in the normal operational range
b. if the radiator has no leaks
c. if the engine has no overheating
7. How many weeks should a coolant hoses be check?
a. a week
b. 2 weeks
c. 3 weeks
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8. What kind of materials constitute the making and production of a
radiator?
a. aluminum
b. carbon
9. How to facilitate the flushing of the cooling system ?
a. disconnect the lower radiator hoses
b. refer the owners manual
c. maintain the level of coolant
10. It is the sytem that maintain the proper engine temperature
a. cooling system
b. fuel system
c. none of the above
True or False: Using blank sheet of paper write true if the statement s
correct and write false if the statement is wrong.
_______1.Can we consider proper maintenance as vital to prolong the
serviceability of the cooling system?
_______2.To avoid accident due to pressurized water vapor from the
radiator, we should tighten the radiator cap
_______3 While working in the shop especially doing repair, are we
required to wear PPE equipment?
_______4.The correct way in removing the radiator is to allow the
coolant to stay inside the radiator.
_______5.If water alone is placed in a radiator without antifreeze would
it bring the engine block to crack.
_______6. When water is coming out the radiator cap. The possible cause
is blown head gasket.
_______7. When the engine is turned off the tendency of the antifreeze
is to solidify.
_______8. Running a cooler thermostat would help the engine to cool
better.
_______9.The meaning of deflection limit is front diameter of the front
Disc
______10. Through observation alone, can be estimate that the standard
specification of the pad lining thickness has change due to worn ou?
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Answer Key
Multiple Choice:
1.b
2.a
3.c
4. a
5.a
6.b
7.a
8.a
9.a
10.a
True or False
1.T
2.T
3.T
4.F
5.T
6.T
7.F
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8.T
9.F
10.T
Performance Test
Specific Instruction:
4. Place a drain pan below the radiator and remove the drain plug;
Revision # 01
reinstallation;
List of Materials: Radiator hose, radiator clamp, bolts and nuts, coolant
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Performance Criteria Checklist for Performance Test
CRITERIA
YES NO
Did you.
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QUESTIONING TOOL
Satisfactory
Questions to probe the candidates underpinning knowledge
response
Extension/Reflection Questions Yes No
1. What are the components of cooling system that need to be
replaced?
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8. Why we need to use the correct tools for a job being
performed?
Rules and Regulations
9. Use the correct tools for the job assigned to you
10. Follow the rules and procedures in performing repair
The candidates underpinning Satisfactory Not
knowledge was: Satisfactory
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Expected Answer for Questioning Tool
Satisfactory
Questions to probe the candidates underpinning knowledge
response
Extension/Reflection Questions Yes No
1. Are the components of cooling system need to be replaced?
2. Are the safety rules and procedures followed?
Safety Questions
3. Did we follow safety rules?
4. Did you repair the leak radiator?
Contingency Questions
5. Did you identify the trouble in the cooling system?
6 Did your materials complete
Job Role/Environment Questions
7. Did we follow the procedure in removing cooling system
parts?
8. Did we used the correct tools for the job being performed?
Rules and Regulations
7. Did we follow the procedure in removing cooling system
parts?
8. Did we used the correct tools in doing repair?
The candidates underpinning Satisfactory Not
knowledge was: Satisfactory
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Inventory of Training Resources
Qualification Title: ____________________________
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Equipment As per TR As per Remarks
Inventory
Note: In the remarks section, remarks may include for repair, for
replenishment, for reproduction, for maintenance etc.
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WORKSHOP LAYOUT
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