KSKV Hydraulic System Repair

MINISTRY OF EDUCATION, MALAYSIA
VOCATIONAL COLLEGE STANDARD CURRICULLUM

COURSE INFORMATION
COURSE NAME
HYDRAULIC SYSTEM REPAIR
CODE NAME
GMA 301
LEVEL
2 SEMESTER 3
CREDIT UNIT
4.0
CONTACT HOUR
FACE TO FACE
: 7.0 HOURS/WEEK (1T+6P)
NON FACE TO FACE
COURSE TYPE
VOCATIONAL
PRE-REQUISITE
CORE REQUISITE
COURSE OUTCOMES
Module Page
1/54
Document Page
At the end of the course, the students should be able to:
Overhaul manual steering box

Overhaul power steering assembly
Repair disc brake assembly
Repair multiple disc brake assembly
Repair brake master cylinder
Repair hydraulic pump
Service hydraulic control valves
COURSE DESCRIPTION
This unit identifies the competence required to overhaul manual steering box using hand tools set, manual steering box service manual, special
tools, steering oil, solvent and log book so that manual steering box service manual obtained, steering box assembly removed, steering box
component dismantled, component defect checked, steering box component assembled, steering box assembly installed and steering box
operations tested in accordance with manufacturers specification.
This unit identifies the competence required to overhaul power steering assembly using hand tools set, power steering system service manual,
pressure gauge, steering oil, solvents, new parts and log books so that power steering system service manual obtained, power steering assembly
removed, power steering component dismantled, power steering component checked, power steering component assembled, power steering
installed and power steering performance tested in accordance with manufacturers specification
This unit identifies the competence required to repair disc brake assembly using hand tools set, disc brake service manual, anti rush, maintenance
check sheet, floor jack, brake fluid, air compressor and new oil seal so that disc brake service manual obtained, tractor wheel removed, disc
brake components dismantled, disc brake components checked, disc brake components assembled, tractor wheel installed and brake performance
tested in accordance with manufacturers specification.
This unit identifies the competence required to repair multiple disc brake assembly using hand tools set, multiple disc brake service manual, anti
rush, maintenance check sheet, floor jack, brake fluid, air compressor and new oil seal so that multiple disc brake service manual obtained,
machine wheel removed, multiple disc brake components dismantled, multiple disc brake components checked, multiple disc brake components
assembled, machine wheel installed and brake performance tested in accordance with manufacturers specification.
Module Page
2/54
Document Page
This unit identifies the competence required to repair brake master cylinder using hand tools set, brake master cylinder service manual, sand
paper, brake fluid, plastic hose, new rubber seal, and log book so that brake master cylinder service manual obtained, brake master cylinder
assembly removed, brake master cylinder component dismantled, brake master cylinder component checked, brake master cylinder component
assembled, brake master cylinder assembly installed and brake master cylinder performance tested in accordance with manufacturers
specification.
This unit identifies the competence required to repair hydraulic pump using hand tools set, hydraulic oil, hydraulic pump service manual, bearing
extractor, measuring equipment, new parts and log book so that hydraulic pump service manual obtained, hydraulic pump removed, pump
components dismantled, pump components checked, pump components assembled, hydraulic pump installed and hydraulic system performance
tested in accordance with manufacturers specification.
This unit identifies the competence required to service hydraulic control valves using hand tools set, hydraulic oil, hydraulic control valves
service manual, bearing extractor, feeler gauge, industrial tissue, flow meter, new parts and log book so that hydraulic control valves service
manual obtained, hydraulic control valves removed, hydraulic control valves components dismantled, control valves components checked,
control valves components assembled, hydraulic control valves installed, hydraulic pump performance tested in accordance with manufacturers
specification.
Module Page
3/54
Document Page
CONTENT AND LEARNING STANDARDS

PROGRAM
AGRICULTURAL MECHANIZATION
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
1. Overhaul
manual steering
box
Module Page
4/54
1
Hrs
LEARNING STANDARD
performance , condition
1.1. Obtain Manual Steering Box
Service Manual
PERFORMANCE CRITERIA
performance,condition, standard
1.1.1
Identify sources of manual steering box service

manual according to manufacturer specification.
1.1.2
Procedures of acquiring manual steering box service

1.1.3
Explain manual steering box service manual

according to manufacturer specification.
1.1.4
Determine source of manual steering box service

1.1.5
Acquire manual steering box service manual

1.1.6
Interpret manual steering box service manual

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.2. Remove Steering Box Assembly
Module Page
5/54
1.2.1
Types of steering box according to manufacturer

specification.
1.2.2
Explain function of manual steering box according

to manufacturer specification.
1.2.3
Explain operation of manual steering box according

1.2.4
Removing steering box assembly according to

manufacturer specification.
1.2.5
Disconnecting external attachment according to

1.2.6
Uninstalling steering arm connection according to

1.2.7
Determine types of steering box according to

1.2.8
Determine function of manual steering box

1.2.9
Determine operation of manual steering box

1.2.10
Disconnect external attachment according to

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.3. Dismantle Steering Box

Component
1.4. Check Component Defect
Module Page
6/54
1.2.11
Uninstall steering arm connection according to

1.2.12
Apply removing steering box assembly procedure

1.3.1
Determine function of steering box components

1.3.2
Procedure of dismantling steering box components

1.3.3
Explain steering box components according to

1.3.4

1.3.5
Apply dismantling steering box components

procedure according to manufacturer specification.
1.3.6
Disassemble steering box components according to

1.4.1
Explain types of steering box components defect

1.4.2
Identify types of measuring tools according to

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.5. Assemble Steering Box

Component
Module Page
7/54
1.4.3
Checking steering box components defect

1.4.4
Checking steering box components from defect

1.4.5
Determine types of steering box components defect

1.4.6
Choose types of measuring equipments according

1.4.7
Inspect steering box components from defect

1.4.8
Apply checking steering box components defect

1.5.1
Explain function of steering box components

1.5.2
Procedure of assembling steering box components

1.5.3
Meticulous when assembling steering box

components according to manufacturer
specification.
1.5.4

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.6. Install Steering Box Assembly
Module Page
8/54
1.5.5
Apply procedure of assembling steering box

specification.
1.6.1
Identify types of steering box according to

1.6.2
Identify function of manual steering box according

1.6.3
Explain operation of manual steering box according

1.6.4
Reinstalling steering arm connection according to

1.6.5
Connecting external attachment according to

1.6.6
Explain procedure of installing steering box

assembly according to manufacturer specification.
1.6.7
Determine types of steering box according to

1.6.8
Determine function of manual steering box

1.6.9
Determine operation of manual steering box

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.7. Test Steering Box Operations
Module Page
9/54
1.6.10
Reinstall steering arm connection according to

1.6.11
Connect external attachment according to

1.6.12
Apply installing steering box assembly procedure

1.7.1
Explain steering box inspection procedure according

1.7.2
Explain steering system performance according to

1.7.3
Method updating log book according to

1.7.4
Inspect steering box system such as
Abnormal sound
Leakage
Smooth running
1.7.5
Apply steering box inspection procedure according

Document Page
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.7.6
Module Page
10/54
Update log book according to manufacturer

specification.
Document Page
10

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
2. Overhaul power
steering
assembly
Module Page
11/54
2
Hrs
LEARNING STANDARD
2.1. Obtain Power Steering System
Service Manual
2.1.1
Identify source of power steering system service

2.1.2
Explain procedures of acquiring power steering

system service manual according to manufacturer
specification.
2.1.3
Explain power steering system service manual

2.1.4
Determine source power steering system service

2.1.5
Acquire power steering system service manual

2.1.6
Interpret power steering system service manual

Document Page
11
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.2. Remove Power Steering
Assembly
Module Page
12/54
2.2.1
Identify types of steering oil according to

2.2.2
Identify types of power steering hoses according to

2.2.3
Identify types of power steering pump according to

2.2.4
Explain function of steering control valve according

2.2.5
Detaching steering cylinder procedure according to

2.2.6
Explain drain steering oil according to manufacturer

specification.
2.2.7
Disconnect hoses and external attachment from

steering system according to manufacturer
specification.
2.2.8
Disconnect steering pump according to

2.2.9
Dismount steering control valve according to

2.2.10
Detach steering cylinder from machine according to

Document Page
12
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.3. Dismantle Power Steering
Component
2.3.1
Explain function of power steering components

2.3.2
Explain procedure of dismantling power steering

specification.
2.3.3
Identify types of solvent according to manufacturer

specification.
2.3.4
Disassemble power steering components such as
Steering pump assembly

Steering control and relief valve assembly
Steering cylinder assembly
2.4. Check Power Steering

Component
Module Page
13/54
2.3.5
Apply dismantling power steering components

2.3.6
Soak parts and component with solvent according

2.4.1
Identify types of power steering component defect

2.4.2
Checking power steering components procedure

2.4.3
Determine types of power steering component

Document Page
13
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
defect according to manufacturer specification.
2.5. Assemble Power Steering

Component
Module Page
14/54
2.4.4
Apply checking power steering components

2.4.5
Replace power steering defective parts according to

2.5.1
Identify function ability of power steering

specification.
2.5.2
Explain procedure of assembling power steering

specification.
2.5.3
Confirming function ability of the components

2.5.4
Reassemble power steering components such as
Steering pump assembly
Steering control and relief valve assembly
Steering cylinder assembly

2.5.5
Apply assembling power steering components

2.5.6
Confirm function ability of the components

Document Page
14
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.6. Install Power Steering
Module Page
15/54
2.6.1
Explain attaching steering cylinder to machine

method according to manufacturer specification.
2.6.2
Explain function of steering control valve according

2.6.3
Explain function of steering pump according to

2.6.4
Identify types steering oil according to

2.6.5
Explain topping up steering oil according to

2.6.6
Attach steering cylinder to machine according to

2.6.7
Identify mount steering control valve according to

2.6.8
Connect steering pump according to manufacturer

specification.
2.6.9
Connect hoses and external attachment to steering

system according to manufacturer specification.
2.6.10
Top up steering oil according to manufacturer

Document Page
15
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
specification.
2.7. Test Power Steering

Performance
Module Page
16/54
2.7.1
Explain engine starting procedure according to

2.7.2
Explain leakage inspect procedure according to

2.7.3
Perform power steering testing procedure according

2.7.4
Explain updating log book according to

2.7.5
Apply engine starting procedure according to

2.7.6
Inspect power steering system leakage according to

2.7.7
Move steering to left and right according to

2.7.8
Justify steering performance according to

2.7.9
Apply power steering testing procedure according to

2.7.10

Document Page
16
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
specification.
Module Page
17/54
Document Page
17

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
3. Repair disc
brake assembly
Module Page
18/54
3
Hrs
LEARNING STANDARD
3.1. Obtain Disc Brake Service
Manual
3.1.1
Explain sources of disc brake service manual

3.1.2
Explain procedures of acquiring disc brake service

3.1.3
Explain disc brake service manual according to

3.1.4
Determine source of disc brake service manual

3.1.5
Acquire disc brake service manual according to

3.1.6
Interpret disc brake service manual according to

Document Page
18
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.2. Remove Tractor Wheel
3.3. Dismantle Disc Brake

Components
Module Page
19/54
3.2.1
Identify types of tractor wheel according to

3.2.2
Identify types of jacking equipment according to

3.2.3
Explain procedure of removing tractor wheel

3.2.4
Determine types of tractor wheel according to

3.2.5
Jack tractor to appropriate height according to

3.2.6
Apply removing tractor wheel procedure according

3.3.1
Identify types of braking system according to

3.3.2
Explain operation of disc brake system Disc brake

piping system according to manufacturer
specification.
3.3.3
Explain dismantling disc brake components

3.3.4
Explain procedure of dismantling disc brake

Document Page
19
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
specification.
3.4. Check Disc Brake Components
Module Page
20/54
3.3.5
Explain spraying disc brake components with

pressured air according to manufacturer
specification.
3.3.6
Determine types of braking system according to

3.3.7
Determine operation of disc brake system according

3.3.8
Disconnect disc brake pipe line according to

3.3.9
Disassemble disc brake components such as
Brake caliper assembly
Brake pads
Piston and seals

3.3.10
Apply dismantling disc brake components procedure

3.3.11
Spray disc brake components with pressured air

3.4.1
Identify types of disc brake components defect

Document Page
20
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.5. Assemble Disc Brake

Components
Module Page
21/54
3.4.2
Checking disc brake components defect procedure

3.4.3
Identify types of measuring equipment according to

3.4.4
Checking brake caliper from crack according to

3.4.5
Inspect pads condition such as
Thickness
Oily
Burn
Crack
3.4.6
Inspect brake caliper from crack according to

3.4.7
Inspect disc condition from scratch, crack and

distortion according to manufacturer specification.
3.4.8
Explain use measuring equipment according to

3.5.1
Identify function of braking system according to

3.5.2
Explain operation of disc brake system according to

Document Page
21
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
Module Page
22/54
3.5.3
Explain assemble disc brake components procedure

3.5.4
Identify types of brake fluid according to

3.5.5
Explain bleeding air from disc brake system method

3.5.6
Explain changing pad and piston seals according to

3.5.7
Explain connecting disc brake pipe line according to

3.5.8
Determine function of braking system according to

3.5.9
Determine operation of disc brake system according

3.5.10
Reassemble disc brake components according to

3.5.11
Change pad and piston seals according to

3.5.12
Connect disc brake pipe line according to

Document Page
22
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.6. Install Tractor Wheel
3.7. Test Brake Performance
Module Page
23/54
3.5.13
Apply assembling disc brake components procedure

3.5.14
Bleed air from brake system according to

3.6.1
Identify types of tractor wheel according to

3.6.2

3.6.3
Explain installing tractor wheel procedure according

3.6.4
Determine types of tractor wheel according to

3.6.5
Apply installing tractor wheel procedure according

3.6.6
Release tractor jack according to manufacturer

specification.
3.7.1
Explain disc brake inspection procedure according

3.7.2

Document Page
23
CONTENT
STANDARD
performance
Module Page
24/54
Hrs
LEARNING STANDARD
3.7.3
Method brake system and ensure tires lock

3.7.4
Checking system from leakage according to

3.7.5
Apply disc brake inspection procedure according to

3.7.6
Apply brake system and ensure tires lock according

3.7.7
Inspect system from leakage according to

3.7.8

specification.
Document Page
24

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
4. Repair multiple
disc brake
assembly
Module Page
25/54
Hrs
LEARNING STANDARD
4.1. Obtain Multiple Disc Brake
Service Manual
4.1.1
Identify sources of multiple disc brake service

4.1.2
Explain procedures of acquiring multiple disc brake

service manual according to manufacturer
specification.
4.1.3
Explain multiple disc brake service manual

4.1.4
Determine source of multiple disc brake service

4.1.5
Acquire multiple disc brake service manual

4.1.6
Interpret multiple disc brake service manual

Document Page
25
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.2. Remove Machine Wheel
4.3. Dismantle Multiple Disc Brake

Components
Module Page
26/54
4.2.1
Identify types of machine wheel according to

4.2.2

4.2.3
Explain removing machine wheel procedure

4.2.4
Determine types of machine wheel according to

4.2.5
Jack machine to appropriate height according to

4.2.6
Apply removing machine wheel procedure according

4.3.1
Identify types of braking system according to

4.3.2
Explain operation of multiple disc brake system

4.3.3
Explain multiple disc brakes piping system

4.3.4
Explain dismantling multiple disc brake components

Document Page
26
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.4. Check Multiple Disc Brake

Components
Module Page
27/54
4.3.5
Determine types of braking system according to

4.3.6
Determine operation of multiple disc brake system/

mechanical brake according to manufacturer
specification.
4.3.7
Disconnect multiple disc brake pipe line according

4.3.8
Disassemble multiple disc brake components such

as
Brake caliper assembly
Brake pads
Piston and seals

4.3.9
Apply dismantling multiple disc brake components

4.3.10
Spray multiple disc brake components with

pressured air according to manufacturer
specification.
4.4.1
Identify types of multiple disc brake components

4.4.2
Explain checking multiple disc brake components

defect procedure according to manufacturer
specification.
Document Page
27
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.5. Assemble Multiple Disc Brake

Components
Module Page
28/54
4.4.3
Identify types of measuring equipment according to

4.4.4
Inspect pads condition such as
Thickness
Oily
Burn
Crack
4.4.5
Inspect brake caliper from crack according to

4.4.6
Inspect disc condition from scratch, crack and

distortion according to manufacturer specification.
4.4.7
Explain Use measuring equipment according to

4.4.8
Meticulous when inspect disc brake defective parts

4.5.1
Explain function of braking system according to

4.5.2
Explain operation of multiple disc brake system

4.5.3
Explain assemble multiple disc brake components

Document Page
28
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
Module Page
29/54
4.5.4
Identify types of brake fluid according to

4.5.5
Explain bleeding air from multiple disc brake system

method according to manufacturer specification.
4.5.6
Determine function of braking system according to

4.5.7
Determine operation of multiple disc brake system

4.5.8
Reassemble multiple disc brake components

4.5.9
Change pad and piston seals according to

4.5.10
Connect multiple disc brake pipe line according to

4.5.11
Apply assembling multiple disc brake components

4.5.12
Bleed air from brake system according to

Document Page
29
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.6. Install Machine Wheel
4.7. Test Brake Performance
Module Page
30/54
4.6.1
Identify types of machine wheel according to

4.6.2

4.6.3
Explain installing machine wheel procedure

4.6.4
Determine types of machine wheel according to

4.6.5
Apply installing machine wheel procedure according

4.6.6
Release machine jack according to manufacturer

specification.
4.7.1
Explain multiple disc brake inspection procedure

4.7.2

4.7.3
Apply multiple disc brake inspection procedure

4.7.4
Apply brake system and ensure tires lock according

Document Page
30
CONTENT
STANDARD
performance
Module Page
31/54
Hrs
LEARNING STANDARD
4.7.5

4.7.6

specification.
Document Page
31

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
5. Repair brake
master cylinder
Module Page
32/54
Hrs
LEARNING STANDARD
5.1. Obtain Brake Master Cylinder
Service Manual
5.1.1
Identify sources of brake master cylinder service

5.1.2
Explain procedures of acquiring brake master

cylinder service manual according to manufacturer
specification.
5.1.3
Explain brake master cylinder service manual

5.1.4
Determine source of brake master cylinder service

5.1.5
Acquire brake master cylinder service manual

5.1.6
Interpret brake master cylinder service manual

Document Page
32
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.2. Remove Brake Master Cylinder
Assembly
Module Page
33/54
5.2.1
Identify types of brake master cylinder according to

5.2.2
Explain function of brake master cylinder according

5.2.3
Explain operation of brake master cylinder

5.2.4
List methods of removing brake master cylinder

5.2.5
Explain disconnecting external piping according to

5.2.6
Explain uninstalling brake master cylinder assembly

5.2.7
Determine types of brake master cylinder according

5.2.8
Determine function of brake master cylinder

5.2.9
Determine operation of brake master cylinder

5.2.10
Drain brake fluid according to manufacturer

specification.
5.2.11
Disconnect external piping according to

Document Page
33
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.3. Dismantle Brake Master

Cylinder Component
Module Page
34/54
5.2.12
Uninstall brake master cylinder assembly according

5.2.13
Follow procedure of removing brake master cylinder

5.3.1
Explain determine function of brake master cylinder

specification.
5.3.2
Explain procedure of dismantling brake master

cylinder components according to manufacturer
specification.
5.3.3
Explain disassembling brake master cylinder

specification.
5.3.4
Explain spraying brake master cylinder components

with compressed air according to manufacturer
specification.
5.3.5

specification.
5.3.6
Apply dismantling brake master cylinder procedure

Document Page
34
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.4. Check Brake Master Cylinder

Component
Module Page
35/54
5.3.7
Disassemble brake master cylinder components

5.3.8
Spray brake master cylinder components with

compressed air according to manufacturer
specification.
5.4.1
Identify types of brake master cylinder components

5.4.2
Explain procedure of checking brake master

cylinder components defect according to
5.4.3
Explain changing brake master cylinder components

defective parts according to manufacturer
specification.
5.4.4
Explain checking brake master cylinder components

from defect according to manufacturer
specification.
5.4.5
Explain conscientious when measure wear parts

5.4.6
Determine types of brake master cylinder

components defect according to manufacturer
specification.
Document Page
35
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.5. Assemble Brake Master Cylinder

Component
5.6. Install Brake Master Cylinder

Module Page
36/54
5.4.7
Inspect brake master cylinder components from

5.4.8
Follow procedure of checking brake master cylinder

specification.
5.4.9
Change brake master cylinder components

defective parts according to manufacturer
specification.
5.5.1
Explain function of brake master cylinder

specification.
5.5.2
Explain procedure of assembling brake master

specification.
5.5.3

specification.
5.5.4
Follow procedure of assembling brake master

specification.
5.6.1
Identify types of brake master cylinder according to

Document Page
36
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
Assembly
Module Page
37/54
5.6.2
Explain function of brake master cylinder according

5.6.3
Explain operation of brake master cylinder

5.6.4
Explain installing brake master cylinder assembly

5.6.5
Explain procedure of installing brake master

cylinder assembly according to manufacturer
specification.
5.6.6
Explain bleeding air from brake system method

5.6.7
Explain topping up brake fluid procedure according

5.6.8
Explain connecting external piping method

5.6.9
Determine types of brake master cylinder according

5.6.10

5.6.11
Method bleed air from brake system according to

Document Page
37
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.7. Test Brake Master Cylinder

Performance
5.6.12
Determine operation of brake master cylinder

5.6.13
Reinstall brake master cylinder assembly according

5.6.14
Connect external piping according to manufacturer

specification.
5.6.15
Apply installing brake master cylinder assembly

5.6.16
Top up brake fluid according to manufacturer

specification.
5.7.1
Explain brake master cylinder inspection procedure

5.7.2
Explain brake system performance according to

5.7.3
Explain update log book according to manufacturer

specification.
5.7.4
Inspect brake master cylinder system such as
Abnormal sound
Leakage
Module Page
38/54
Document Page
38
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
Smooth running
Module Page
39/54
5.7.5
Apply brake master cylinder inspection procedure

5.7.6

specification.
Document Page
39

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
6. Repair hydraulic
pump
Module Page
40/54
Hrs
LEARNING STANDARD
6.1. Obtain Hydraulic Pump Service
Manual
6.1.1
Identify source of hydraulic pump service manual

6.1.2
Explain procedures of acquiring hydraulic pump

service manual according to manufacturer
specification.
6.1.3
Explain hydraulic pump service manual according to

6.1.4
Determine source of hydraulic pump service manual

6.1.5
Acquire hydraulic pump service manual according

6.1.6
Interpret hydraulic pump service manual according

Document Page
40
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.2. Remove Hydraulic Pump
6.3. Dismantle Pump Components
Module Page
41/54
6.1.7
Interpret hydraulic pump circuit according to

6.2.1
Identify types of hydraulic pump according to

6.2.2
Identify hydraulic system according to manufacturer

specification.
6.2.3
Identify types of hydraulic oil according to

6.2.4
Explain procedure of removing hydraulic pump

6.2.5
Determine types of hydraulic pump according to

6.2.6
Depressurize hydraulic system according to

6.2.7
Disconnect hydraulic linkages according to

6.2.8
Uninstall hydraulic pump assembly according to

6.3.1
Explain procedure of dismantling hydraulic pump

parts and components according to manufacturer
specification.
Document Page
41
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.4. Check Pump Components

Module Page
42/54
6.3.2
Identify types of solvent according to manufacturer

specification.
6.3.3
Method disassembles pump parts and components

6.3.4
Method washing pump parts and component with

solvent according to manufacturer specification.
6.3.5
Method uninstalling cap screws and washers

6.3.6
Mark pumps end cover according to manufacturer

specification.
6.3.7
Uninstall cap screws and washers according to

6.3.8
Lift off pump port and cover according to

6.3.9
Determine disassemble pump parts and

specification.
6.3.10
Wash pump parts and component with solvent

6.4.1
Identify types of hydraulic pump components defect

Document Page
42
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.5. Assemble Pump Components
Module Page
43/54
6.4.2
Explain procedure of inspection of pumping element

specification.
6.4.3
Method measuring bearing from roughness,

excessive wears and damage races technique
6.4.4
Method changing oil seals, O rings and bearing

6.4.5
Scrap pump parts cavities according to

6.4.6
Inspect pumping element from defect according to

6.4.7
Inspect bearing from roughness, excessive wear

and damage races according to manufacturer
specification.
6.4.8
Change oil seals, O rings and bearing according to

6.5.1
Explain procedure of assembling pump parts and

specification.
6.5.2
Method inserting pump port and cover technique

Document Page
43
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.6. Install Hydraulic Pump
Module Page
44/54
6.5.3
Explain confirming pump end cover marking

6.5.4
Method tightening cap screws and washers

6.5.5
Reassemble pump parts and components according

6.5.6
Insert pump port and cover according to

6.5.7
Confirm pump end cover marking according to

6.5.8
Tighten cap screws and washers according to

6.6.1
Identify types of hydraulic pump according to

6.6.2
Explain installing hydraulic pump procedure

6.6.3
Explain fixing hydraulic linkages according to

6.6.4
Determine types of hydraulic pump according to

Document Page
44
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.7. Test Hydraulic Pump

Performance
Module Page
45/54
6.6.5
Reinstall hydraulic pump assembly according to

6.6.6
Fix hydraulic linkages according to manufacturer

specification.
6.7.1

6.7.2
Explain operating hydraulic system according to

6.7.3
Method testing hydraulic pump performance

6.7.4
Method inspecting system from leakage according

6.7.5
Method switching off engine according to

6.7.6

6.7.7
Apply engine starting procedure according to

6.7.8
Operate hydraulic pump system according to

6.7.9
Apply testing hydraulic pump performance

Document Page
45
CONTENT
STANDARD
performance
LEARNING STANDARD
Hrs
6.7.10

6.7.11
Switch off engine according to manufacturer

specification.
6.7.12

specification.

PROGRAM
COURSE NAME
CODE NAME
GMA 301
COMPETENCY
CONTENT
STANDARD
performance
7. Service
hydraulic
control valves
Module Page
46/54
7
Hrs
LEARNING STANDARD
7.1. Obtain Hydraulic Control Valves
Service Manual
7.1.1
Identify source of hydraulic control valves service

7.1.2
Explain procedures of acquiring hydraulic control

valves service manual according to manufacturer
Document Page
46
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
specification.
7.2. Remove Hydraulic Control

Valves
Module Page
47/54
7.1.3
Identify hydraulic control valves service manual

7.1.4
Determine source of hydraulic control valves service

7.1.5
Acquire hydraulic control valves service manual

7.1.6
Interpret hydraulic control valves service manual

7.1.7
Interpret hydraulic control valves circuit according

7.2.1
Identify types of hydraulic valves according to

7.2.2
Identify hydraulic control valves according to

7.2.3
Identify types of hydraulic oil according to

7.2.4
Explain procedure of removing hydraulic control

valves according to manufacturer specification.
Document Page
47
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.3. Dismantle Hydraulic Control

Valves Components
7.4. Check Control Valves

Components
Module Page
48/54
7.2.5
Determine types of hydraulic control valves

7.2.6
Depressurize hydraulic system according to

7.2.7
Disconnect hydraulic linkages according to

7.2.8
Uninstall hydraulic control valves according to

7.3.1
Identify Type of hand tools according to

7.3.2
Explain Procedure of dismantling hydraulic control

valves parts and components according to
7.3.3
Choose type of hand tools according to

7.3.4
Disassemble hydraulic control valve components in

sequence according to manufacturer specification.
7.4.1
Identify types of hydraulic control valves

specification.
Document Page
48
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.5. Assemble Control Valves

Components
Module Page
49/54
7.4.2
Explain procedure of Inspection of control valves

specification.
7.4.3
Method measuring worn out parts technique

7.4.4
Method changing defect parts according to

7.4.5

specification.
7.4.6
Inspect control valves components defects

7.4.7
Measure worn out parts according to manufacturer

specification.
7.4.8
Change defect parts according to manufacturer

specification.
7.5.1
Explain procedure of assembling control valves

specification.
7.5.2
Method Inserting control valves inner parts

technique according to manufacturer specification.
7.5.3
Follow procedure of reassembling control valves

Document Page
49
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
specification.
7.6. Install Hydraulic Control Valves
7.7. Test Hydraulic Pump

Performance
Module Page
50/54
7.5.4
Insert control valves inner parts according to

7.6.1
Identify Types of hydraulic control valves according

7.6.2
Explain Function of hydraulic control valves

7.6.3
Method of reinstalling hydraulic control valves

7.6.4

7.6.5
Apply method reinstall hydraulic control valves

7.6.6
Fix hydraulic linkages according to manufacturer

specification.
7.7.1

7.7.2
Explain operating hydraulic system according to

Document Page
50
CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.7.3
Explain procedure of testing hydraulic performance

7.7.4
Apply engine starting procedure and set to

manufacturer recommended load according to
7.7.5
Explain hydraulic flow in different situation such as
Zero pressure
250 p.s.i
Module Page
51/54
7.7.6
Method checking system from leakage according to

7.7.7
Method switching of engine according to

7.7.8

7.7.9
Setup flow meter at outlet port of reservoir

7.7.10
Operate hydraulic control valves system or

implement function according to manufacturer
specification.
7.7.11
Open hydraulic tester load valve according to

Document Page
51
CONTENT
STANDARD
performance
Module Page
52/54
Hrs
LEARNING STANDARD
7.7.12
Apply procedure of engine starting and set to

manufacturer recommended load according to
7.7.13
Determine hydraulic flow in different situation

7.7.14

7.7.15
Switch of engine according to manufacturer

specification.
7.7.16

specification.
Document Page
52

KSKV Hydraulic System Repair

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

KSKV Hydraulic System Repair

Încărcat de

Drepturi de autor:

Formate disponibile

MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULLUM

HYDRAULIC SYSTEM REPAIR

: 7.0 HOURS/WEEK (1T+6P)

NON FACE TO FACE

At the end of the course, the students should be able to:

Overhaul manual steering box

CONTENT AND LEARNING STANDARDS

HYDRAULIC SYSTEM REPAIR

Identify sources of manual steering box service

Procedures of acquiring manual steering box service

Explain manual steering box service manual

Determine source of manual steering box service

Acquire manual steering box service manual

Interpret manual steering box service manual

Types of steering box according to manufacturer

Explain function of manual steering box according

Explain operation of manual steering box according

Removing steering box assembly according to

Disconnecting external attachment according to

Uninstalling steering arm connection according to

Determine types of steering box according to

Determine function of manual steering box

Determine operation of manual steering box

Disconnect external attachment according to

1.3. Dismantle Steering Box

1.4. Check Component Defect

Uninstall steering arm connection according to

Apply removing steering box assembly procedure

Determine function of steering box components

Procedure of dismantling steering box components

Explain steering box components according to

Determine function of steering box components

Apply dismantling steering box components

Disassemble steering box components according to

Explain types of steering box components defect

Identify types of measuring tools according to

1.5. Assemble Steering Box

Checking steering box components defect

Checking steering box components from defect

Determine types of steering box components defect

Choose types of measuring equipments according

Inspect steering box components from defect

Apply checking steering box components defect

Explain function of steering box components

Procedure of assembling steering box components

Meticulous when assembling steering box

Determine function of steering box components

1.6. Install Steering Box Assembly

Apply procedure of assembling steering box

Identify types of steering box according to

Identify function of manual steering box according

Explain operation of manual steering box according

Reinstalling steering arm connection according to

Connecting external attachment according to

Explain procedure of installing steering box

Determine types of steering box according to

Determine function of manual steering box

Determine operation of manual steering box

1.7. Test Steering Box Operations

Reinstall steering arm connection according to

Connect external attachment according to

Apply installing steering box assembly procedure

Explain steering box inspection procedure according