2005 us army student guide 69p

7/27/2019 2005 US Army Student Guide 69p

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62B10 (R) ADT, PHASE 2

CONSTRUCTION EQUIPMENT REPAIRER

STUDENT GUIDE


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SHOP OPERATIONS

PRACTICAL EXERCISE SHEET 62B10A07PE1

Title Proper Use of Tools.

Lesson Number/ Title

62B10A02 version ADT / Employ Test, Measurement and Diagnostic Equipment(TMDE), general mechanics and special tools.

Student Materials:

Student Guide

Pens and Pencils

Procedures:

Station One:

At this station you have a piece of round stock and a piece of bar stock. Using TM 9-243 and guidance from theinstructor, you must:

1. Properly install the blade in the hacksaw.

2. Cut the round stock and bar stock to a specified length.

3. Use the correct file and remove any rough edges or burrs from the metal.

4. Use the center punch and mark the bar stock for drilling.

NOTE: The instructor will inform you of the correct drill twist to use.

5. Select the correct drill twist size.

6. Install and secure the drill twist in the drill properly.

7. Properly drill the hole without causing damage to the equipment or personnel injury.

8. Use the file to remove any burrs or rough edges as required.

9. Remove the drill twist from the drill and place it back in the set.

Station Two:

At this station you have the piece of round stock and the piece of bar stock with the hole in it from station #2. Using TM 9-243 and guidance from the instructor, you must:

1. Properly position the metal in the vice.

NOTE: The instructor will tell you which size to use for item # 2 & 3.

2. Select the proper tap and die.

3. Properly use the tap to cut internal threads in the piece of flat stock.

4. Properly use the die to thread the round stock.

5. Insure that the threaded round stock fits the square stock you threaded.


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6. Clean and return the tap and die to their proper locations.

Station Three:At this station you have a piece of copper tubing, a tube cutter, and a flaring tool kit. Using TM 9-243 and guidance fromthe instructor, you must make a single and double flare to a piece of copper tubing IAW the TM and instructor guidance.

1. Use the TM.

2. Inspect the tools you will be using.

NOTE: The instructor will tell you which size to use for item # 3.

3. Select the proper size die block.

4. Use the tube cutter to properly cut a specified length of tubing.

5. Properly use the reamer to remove any burrs from cutting.

6. Properly position the tubing in the die block.

7. Perform a single flare IAW the TM.

8. Turn the piece of tubing over and repeat steps # 5 and 6.

9. Select the proper adapter and make a double flare to the tubing.

9. Inspect the flares for breakage or cracks.

10. Re-flare the tubing if it is cracked or broken.

11. Clean and secure all tools when the exercise is complete.

Station Four:

Using a torque wrench, properly tighten bolts the instructor has pointed out to the prescribed specifications.


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ELECTRICAL SYSTEMS

PRACTICAL EXERCISE SHEET 62B10B01PE 1

Title Identify Wiring Schematics

Lesson Number / Title 62B10B01 version ADT / Electrical Systems

Resource Requirements

Student Materials:

* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P

* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 11-6625-3199-14* TM 5-3805-262-20 wiring schematics* Student guides* Multicolor marking pens* Pens and pencils

Procedures:

Identify Wiring Schematics:

Problem #1: Using the MW24C Scoop Loader schematic and the study guide identify either a symbol or a componentas required.

1) Locate the fixed resistor in front of the clutch pressure switch.

2) Locate the variable resistor at the water temperature sender.

3) Located the single pole/single throw switch in the upper cab.

4) Locate the N. O. cab relay in the engine compartment.

5) Locate the 30-amp circuit breaker above the cab relay.

6) Locate the single filament bulb at the rear flood lamp.

7) Locate the double filament bulb at the rear tail and stop service lamp.

8) Locate the ground at the negative battery cable.


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9) Locate the defroster motor in the upper cab.

10) Locate the air pressure gage at the left instrument panel.


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Problem #2: Using a red pen, trace a circuit to determine how power gets to the ignition key switch identifyingcomponents, wiring numbers and colors during the process.

Starting at the battery ground, follow the wire to the negative terminal of the first battery. Then leave the positive terminalof the same battery, following the wire to the negative terminal of the second battery. Follow the wire from the positiveterminal of the second battery to the B terminal of the starter solenoid. Now continue on by following that same wire to thestarter relay. From there take the red wire to the lower 30-amp circuit breaker. Next keep with the same red wire to theupper 30-amp circuit breaker. Going through that circuit breaker pick up the two-red/black wires and trace them to theharness/cable connector, pins 16 & 18 of the rear wiring harness. Continue through the connector to the front wiringharness on the same pin numbers and colored wires. Trace it over to the ignition key switch Batt. Terminal.

You have now determined how power gets to the ignition key switch.


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Problem #3: Using a blue pen, trace the circuit that sends power from the ignition key switch to engage the startermotor, identifying components, wiring numbers and colors during the process.

Start at the ignition key switch. Look on the backside of the switch for the start terminal. Follow the white wire to theneutral start switch. Go through the neutral start switch, leaving it on a VIO/BLK wire, going to the bottom left terminal ofthe starter relay. Now the starter relay is energized and the contacts closed. Leave the top left terminal of the starter relayand follow it to the S terminal of the starter solenoid. This will energize the starter solenoid closing its contacts. Now tracethe wire leaving the M terminal over to the starter motor, go through the starter motor to the ground.


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Title Identify the purpose of a battery, battery components, maintenance, safety, andenvironmental procedures.


62B10B01 version ADT / Electrical Systems

Student Materials:

* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20

* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 11-6625-3199-14* TM 5-3805-262-20 wiring schematics* Student guides* Multicolor marking pens* Pens and pencils* Rubber Apron* Rubber Gloves* Safety Goggles

Procedures

Problem #1 Perform a specific gravity test on a battery IAW TM 9-6140-200-14. Annotate the results on the practicalexercise work sheet in your study guide. When all students have completed this task the instructor will goover the results with the entire group.

Cell readings:

Cell One

Cell Two

Cell Three

Cell Four

Cell Five

Cell Six

Difference between highest and lowest cells


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Problem #2 Perform a fixed load test on a battery IAW the instructors guidance, manufactures instructions and theappropriate technical manuals. Annotate the results on the practical exercise work sheet in your study guide. When allstudents have completed this task the instructor will go over the results with the entire group.

Readings:BeforeDuringAfter

Problem #3 Properly recharge a battery IAW the instructors guidance, manufactures instructions and the appropriatetechnical manuals.

NOTE: Since battery chargers are not all alike, ensure you follow the instructors guidance when connecting thecharger to the battery.

NOTE: The voltage in each battery depends on the condition of the batteries. The setup of the battery chargers

may vary depending on the type and capabilities of the charger. This is why it is very important to use themanufacturers manual.


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Title Identify TMDE used for electrical system testing.



Student Materials:

* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 11-6625-3199-14* TM 5-3805-262-20 wiring schematics* Student guides* Multicolor marking pens* Pens and pencils

Procedures:

Group one:

Utilizing the appropriate TM the primary instructor will go through step-by-step procedures for the following:

1. Power up the SPORT or MSD in TK mode.

2. Perform battery voltage test.

3. Perform voltage output test, 0 to 45 volts DC.

4. Perform current output test, 0 to 1500 amps DC.

5. Power down the SPORT or MSD.


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Group two:

Utilize a multimeter along with the knowledge you have gained in the previous electrical classes to perform the followingtasks:

1. Properly test all components of circuit boards for serviceability.

2. Follow the schematic to properly wire circuit board so turn signals and high/low beam lights work.

3. Answer instructors questions pertaining to automotive electricity.

4. Take circuit board to instructors table for operational test.


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Title Troubleshoot a starting and charging system.



Student Materials:

* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 11-6625-3199-14* TM 5-3805-262-20 wiring schematics* Student guides* Multicolor marking pens* Pens and pencils

Procedures:

Site #1: Troubleshoot a starting system utilizing a digital multimeter:

a) Locate components on MW24C wiring schematic

b) Locate components on the MW24C

c) Set multimeter up for the following measurements:

(1) Amperage DC

(2) Resistance

(3) Continuity

(4) Voltage DC

d) Utilize a digital multimeter to perform a battery voltage test troubleshoot

e) Locate Starter Does Not Crank deficiency in the TM troubleshooting chart.


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f) Follow sequence outlined in the troubleshooting chart. g) Informinstructor of the fault when identified.

Site #2: Troubleshoot a starting and charging system utilizing a MSD /SPORT

You will utilize a SPORT / MSD to diagnose the following situations:

a) On the D7G Dozer in DCA mode run the complete GO chain and the following test from the NO GOchain.

(1) NG50 Test #82 Alternator voltage output.

(2) NG50Test #84 Alternator negative cable voltage drop.

(3) NG80 Test #74 Starter circuit resistance.

(4) NG80Test #68 Starter motor voltage.

(5) NG81 Test #75 Battery internal resistance change.

(6) NG81 Test #73 Battery internal resistance

b) On the SEE Tractor in DCA mode run the complete GO (G) chain and the following test from the NOGO chain.

(1) NG50 Test #82 Alternator output voltage.

(2) NG50 Test #84 Alternator negative cable voltage drop.

(3) NG80 Test #74 Starter circuit resistance.

(4) NG80Test #68 Starter motor voltage.

(5) NG81 Test #75 Battery internal resistance change.

(6) NG81 Test #73 Battery internal resistance.

c) On the MW24C Scoop Loader in TK mode go through the starting system troubleshooting chart (PG3-266 PARA 3-33)


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Site #3: Troubleshoot accessory circuits utilizing the digital multimeter

You will utilize a digital multimeter to troubleshoot the following faults:

a) On the MW24C Scoop Loader, utilize a digital multimeter to troubleshoot the following deficiency: Lightsinoperative

b) On the 130G Road Grader, utilize a digital multimeter to troubleshoot the following deficiency.

(1) EMS panel not working properly

(2) Blade float switch inoperative


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Title Replace a switch, replace batteries, and repair a wiring harness.

Lesson Number

/ Title

62B10B01 version ADT / Electrical Systems

Student Materials:

TM 5-3805-261-20

TM 5-3805-262-20

Procedures:

Station # 1:

At this station you (the student) have a MW24C Scooploader with the fault "Bucket does not return to digging position".Using the TM provided, follow the instructor's guidance and the troubleshooting procedures to determine the fault andcorrect it. Perform all actions without damage to the equipment or injury to personnel.

Station # 2:

At this station you (the student) have a MW24C with the fault "Engine will not crank". Using the TM provided, follow theinstructor's guidance and troubleshooting procedures to determine the fault and correct it. Perform all actions withoutdamage to the equipment or injury to personnel.

Station # 3:

At this station you (the student) have a Grader with the fault "All driving, tail and panel lights fail to operate". Using the TMprovided, follow the instructor's guidance and troubleshooting procedures to determine the fault and correct it. Perform allactions without damage to the equipment or injury to personnel.


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DIESEL ENGINE SYSTEMS

PRACTICAL EXERCISE SHEET 62B10C01 PE1

Title Disassemble a diesel engine.


62B10C01 version ADT / Diesel Engine Systems

Procedures:

NOTE: These procedures are based on the use of a CAT 3304 engine. Eachschool should adjust the procedures to accommodate the engine beingused.

1. DISASSEMBLY OF ENGINE

A. REMOVAL OF ELECTRICAL SYSTEM COMPONENTS

1) Removal of Alternator

a. Tag all wires connected to alternator to ensure proper installation during reassembly.

b. Remove hold down nuts from positive and negative wires on alternator and removewires. Reinstall nuts on alternator.

c. Loosen mounting bolts and support bracket bolts. Move alternator towards engine toloosen drive belts.

d. Remove drive belts from alternator pulley and let hang from fan pulley.

e. Remove alternator, alternator support bracket and all mounting nuts, bolts/spacers.Place support bracket, nuts/bolts and spacers in can mark ALT. Place alternator onshelf underneath workbench.

NOTE: Alternator may be heavy.

2) Removal of Starter

a. Tag all wires connected to starter to ensure proper installation during reassembly.

b. Remove wire-mounting nuts from positive and negative posts of starter. Removewire-mounting screw from solenoid.

c. Remove positive and negative wires (large black leads) and solenoid wire fromstarter. Gather all loose wiring together and fold back onto engine stand behind slavecable connector. DO NOT leave wiring on floor.

d. Reinstall wire mounting nuts and screw on starter.

e. Have one student support starter while others remove three (3) starter-mountingbolts.


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NOTE: Starter weighs 65 pounds.

f. Remove starter from engine and wrap in white mat and place on top of workbench.Have students retain starter mounting bolts and gasket for installation of engineturning tool.

3) Installation of Engine Turning Tool

a. Mount engine turning tool in place of starter with flat side of gear shaft supportbracket facing out using starter gasket and three (3) starter mounting bolts. Tightenstarter bolts using 5/8 boxed-end wrench.

b. Insert small end of geared shaft into hole in support bracket. Geared end mustengage ring gear on flywheel.

c. When complete, small-geared end of shaft should engage flywheel ring gear andshaft should move freely in and out of hole. Lubricate shaft as needed.

B. ENGINE ROTATION TO TOP CENTER COMPRESSION POSITION FOR #1 PISTON

1) Students will look up/read the procedure and attempt to explain how and why it is accomplishedto the instructor.

NOTE: Ask students to determine which method they will use, Timing Pointer or Timing Bolt Hole? ANSWER:TIMING BOLT HOLE

NOTE: Ask students, "What is the normal direction of rotation for this engine?" The answer is counterclockwisewhen viewed from the flywheel end.

NOTE: Ask students, "Why must the engine be rotated clockwise?" The answer is to remove play from the timinggears.

2) Students will utilize the 1/2" ratchet for this procedure. Ratchet will be replaced in bottom oftoolbox when procedure is completed.

3) To achieve 30 clockwise rotation, place ratchet in end of turning tool with handle of ratchetpointed down and touching the side of engine. Pull up on handle and rotate engine with ratchetuntil ratchet handle is all the way up and touching the side of engine. Ratchet will be turnedseven (7) times in this manner to achieve 30 clockwise rotation.

4) To rotate engine counterclockwise, reverse ratchet and push down on handle.

5) After engine has been rotated clockwise, remove plug from timing bolt hole and place in canmarked FUEL INJECTION PUMP & GOVERNOR.

6) Insert 3/8" bolt in timing bolt hole and have students rotate engine counterclockwise whileapplying finger pressure to 3/8" bolt. When bolt slides into hole provided in flywheel, the No. 1piston is at top center.

7) Students will check rocker arm assembly per instructions in manual to determine if engine is inTop Center Compression Position for No. 1 piston. Students will raise their hand when finishedand wait for instructor.


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8) Instructor should check rocker arm assemblies of other pistons before checking the rocker armassemblies of No. 1 piston. If timing is incorrect, ask students how they checked timing andwhich rocker arm assembly is for No. 1 piston. Explain procedure for checking timing and havestudents remove bolt from timing hole, slightly rotate engine counter-clockwise, reinsert bolt intiming hole, and continue to rotate engine until bolt slides into flywheel again. Instructor willcheck engine to insure correct timing.

C. REMOVAL OF AIR INDUCTION SYSTEM COMPONENTS

1) Removal of Air Cleaner Assembly

a. Loosen large hose clamp (on turbocharger side) of rubber coupling connecting aircleaner to turbocharger.

b. Remove two (2) nuts and two (2) bolts holding air cleaner assembly to supportbracket at rear of engine.

c. Remove air cleaner assembly from engine.

d. Reinstall nuts and bolts on bracket.

e. Cover/tie off all openings with rags and store air cleaner assembly at end of workbench with filter housing on floor and elbow turned underneath shelf.

2) Removal of Air Inlet Elbow

a. Disconnect and cap airline leading to governor

b. Remove four (4) bolts securing air inlet elbow to intake manifold. Ensure air intakemanifold head bolt is not removed.

c. Remove bolt and washer securing inlet elbow to turbocharger.

d. Twist air inlet elbow up and away from intake manifold and carefully pull it out of theturbocharger.

e. Leave gasket in place on intake manifold and reinstall bolts in intake manifold.Reinstall bolt and washer in turbocharger.

f. Cover/tie off all openings with rags and store air inlet elbow on shelf.

3) Removal of Exhaust Pipe

a. Hold exhaust pipe and remove two (2) nuts and bolts holding exhaust pipe to exhaustmanifold.

b. Hold exhaust pipe to turbocharger coupling and remove exhaust pipe and couplingfrom turbocharger as a unit. (Coupling is cast metal and may crack or break ifdropped).

c. Place exhaust pipe and coupling assembly on workbench and pull coupling fromexhaust pipe.

d. Wrap coupling in rag and place in can marked TURBO.


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e. Cover/tie off openings of exhaust pipe and place on shelf.

f. Reinstall nuts and bolts on exhaust manifold and place large plastic cap over impellerin turbocharger.

4) Removal of Turbocharger

NOTE: There is the potential for oil spillage during the next step.

a. Loosen two (2) bolts holding turbocharger oil feed tube to turbocharger.

b. Slightly loosen fitting holding oil feed tube to engine.

c. Remove two (2) bolts holding oil feed tube to turbocharger.

d. Completely loosen fitting holding oil feed tube to engine and remove tube fromengine. Immediately place thumb over end of tube to prevent oil from leaking out.

e. Keeping thumb over end of tube, remove tube from engine and poor any oil trappedin tube into valve train/rocker arm assembly.

f. Cover/tie off both ends of tube and place on shelf.

g. Cap oil hole in turbocharger and oil feed fitting on engine. Use cap large enough to fitover threads on fitting.

h. Remove four (4) nuts and bolts holding turbocharger to exhaust manifold.

i. Remove turbocharger from exhaust manifold. Oil return line will be removed with theturbocharger. Do not remove it from the turbocharger.

j. Cover/tie off exposed openings on turbocharger and oil return tube. Place on shelf.

k. Reinstall nuts/bolts and gasket (if removed) in exhaust manifold. Cover/tie offopening in exhaust manifold and place cap in oil return tube hole.

D. REMOVAL OF COOLING SYSTEM COMPONENTS

1) Removal of Water Pump

a. One member of group will open drain cock on water pump and use black bucketprovided to drain system of water. Buckets will be dumped outside, away frombuilding.

b. Remove radiator support bracket, reinstall bolts/nuts on engine and bracket. Place

bracket on shelf.

c. Remove upper radiator hose and clamps, cover/tie off ends and place on shelf.

d. Remove mounting bolts to BOTH sections of fan guard, remove fan guard, place onfloor under workbench, and reinstall bolts in radiator shroud.

NOTE: It may be necessary to rotate fan blade in order to remove fan guard from engine.


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e. Loosen two (2) lower water pump hose clamps and slide water pump lower hose offpump.

f. Loosen two (2) hose clamps from oil cooler tube and slide hose onto tube.

g. Remove two (2) bolts (one long, one short) from upper water pump elbow housing.

h. Remove two (2) long bolts (one at bottom right, one at top left) from water pumphousing.

i. Pull water pump away from engine and remove.

j. Reinstall upper gasket (if removed) and four bolts in engine block.

k. Cover/tie off all exposed openings on pumps and engine. Place water pump on shelf.

2) Removal of Water Temperature Regulator

a. Remove four (4) bolts from water temperature regulator housing.

b. Remove water temperature regulator housing and carefully remove gasket betweentemperature regulator housing and cylinder head.

c. Remove water temperature regulator from engine, place inside regulator housing,wrap housing in rag and place in can marked TEMP REG.

d. Reinstall gasket and bolts on engine. Cover/tie off all openings.

E. REMOVAL OF FUEL SYSTEM COMPONENTS

1) Removal of Fuel Injection Lines

NOTE: All personnel must wear safety goggles/glasses during fuel procedures. THIS INCLUDESINSTRUCTORS.

NOTE: There is the potential for fuel spillage during the next steps.

a. Students will utilize 3/4" line wrench to loosen all fuel injection line nuts beginning withNo. 1 injector line at the fuel injection pump housing. Loosen all nuts on the fuelpump from front to rear.

b. Loosen the fuel injection line nuts at the fuel injection valves working from front torear. Hold the top of each fuel injection valve with a 15/16 wrench and loosen fuelinjection line nut with a 3/4" line wrench.

c. Once all nuts are loosened, screw all nuts off by hand. Grasp injector line assembly,lift up and invert assembly over engine to prevent excess fuel spillage, and placeinverted assembly on workbench.

d. Install screw-in type protector caps on ends of fuel line nuts and place assemblycarefully on shelf.

e. Install push-on type protector caps on fuel injection valves and fuel pump.


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f. Place fuel injection line assembly underneath workbench. DO NOT place any othercomponents ON TOP of assembly.

2) Removal of Fuel Filters and Supply/Return Lines

a. Loosen fuel line nuts on fuel line between primary fuel filter and fuel transfer pumpand remove. Loosen fuel line nut on fuel return line connected to the fuel injectionpump. Cover/plug ends of supply and returns lines. Place fuel supply lineunderneath the workbench and ensure students do not set anything on top of it. Foldfuel return line down along side of engine stand. Do not let fuel return line hang or layon floor.

b. Install push on type plastic cap OVER fuel inlet and return fittings on base.

c. Grasp fuel filter with two hands and turn to the RIGHT to loosen. If filter will notloosen by hand students will inform instructor. After filter is loosened, unscrew it fromthe base with one hand while supporting it from the bottom with the other hand.

NOTE: Filter is full of fuel and will spill if tilted.

d. Place filter in can marked FUEL FILTER. Pack rags between filter and sides of can.Cover top of can with rag. This will prevent the filter from tipping and spilling and willkeep contaminants out of fuel.

e. Place push on type plastic cap over threads of fuel filter mounting base.

NOTE: Use dry sweep to clean up any fuel spilled at this point.

3) The following components/accessories must be removed prior to removing the Fuel InjectionPump and Governor Assembly. Students in each group should work individually or in pairs toaccomplish these tasks.

a. Remove two (2) bolts securing exhaust manifold heat shield to mounting brackets.

Place heat shield underneath workbench.

b. Loosen nut on end of tube between air inlet elbow and air/fuel ratio control. Removeline and cap/plug both ends. Cap fitting on air/fuel ration control. Place line underworkbench. DO NOT place any other components ON TOP of line.

c. Unplug harness connecting two (2) wires to fuel shut-off solenoid.

d. Remove six (6) bolts securing fuel injection pump support bracket to engine block andfuel injection pump. Remove support bracket ensuring all O-rings are accounted for.Wrap support bracket in rags and place in FUEL INJ PUMP can.

e. Remove six (6) nuts and washers from timing gear cover studs. Remove timing gear

cover and place on workbench. Place all nuts and washers in timing gear cover onworkbench. Timing gear cover will be reinstalled once fuel injection pump is removed.

f. Use a 15/16" socket and breaker bar and push downward to loosen drive gear bolt.Remove bolt and washer by hand and place in can marked FUEL INJ PUMP & GOV.Return breaker bar to bottom of toolbox.

NOTE: Instructor must check fuel pump timing gear to insure it is loose from the drive sleeve. If it is not loose,INSTRUCTOR will utilize gear puller to free it.


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4) Removal of Fuel Injection Pump and Governor Assembly

NOTE: Fuel Injection Pump weighs approximately 53 lbs.

NOTE: There is the potential for fuel/oil spillage during the next steps.

a. Fuel pump is mounted to engine using three studs with washers and nuts. Use a9/16 boxed-end wrench to remove the BOTTOM two (2) nuts and washers. Onestudent will support fuel pump while the TOP nut and washer is removed using thefollowing tool combination IN ORDER: 9/16 socket, 5" and 10" extension, universaljoint and speeder bar. Two (2) students will carry the fuel injection pump to theworkbench.

NOTE: Instructor will monitor students as fuel pump and governor assembly is removed from studs and placedon workbench.

b. Fuel injection pump will be positioned on workbench the back of pump rests on shortwooden block provided. Position pump on workbench, leaving room for cylinder headplacement.

c. Inspect the bottom of fuel injection pump for the presence of two (2) O-ring seals.Inspect the front of the fuel injection pump for the presence of two (2) O-ring seals. Ifany O-ring is missing, look for it on and around engine or on the ground. If it cannotbe found, replace.

NOTE: Use dry sweep to clean up any fuel spilled at this point.

d. Cover entire fuel pump with large rag. Reinstall timing gear cover on engine andhand tighten nuts. Cover/tie off opening where the fuel injection pump was removedfrom.

F. REMOVAL OF EXHAUST SYSTEM COMPONENTS

1) Removal of Exhaust Manifold

a. Remove nuts, brackets, and the washers BETWEEN the No. 1 and No. 2 cylindersand between the No. 3 and No. 4 cylinders and place in EXH MAN can.

b. One student will support and hold the exhaust manifold while the remaining two (2)nuts are loosened. Remove remaining nuts and washers and place in can withothers.

NOTE: Exhaust manifold is heavy and fragile.

c. Using a two-person carry, carefully remove exhaust manifold from engine and placeon floor. Cover/tie off all openings in exhaust manifold and place it on floor UNDER

the workbench.

d. Remove exhaust manifold gaskets from engine, wrap together in rag and place inEXH MAN can.

e. Place rag in each hole of cylinder head created by removal of exhaust manifold. Donot let rags hang down below cylinder head.

G. REMOVAL OF ROCKER ARM ASSEMBLY AND PUSH RODS


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1) Removal of Rocker Arm Assembly

a. Remove rocker arm cover and place upside down directly in front of radiator.

b. Make six (6), one (1) ft square rags and remove any loose hanging threads and tuckone rag into hole around each set of push rods.

NOTE: Locknuts and adjustment screws have sharp burrs. Use care when loosening locknuts to avoid cutsand scrapes on hands.

c. Loosen valve adjustment locknut, back out adjustment screw two (2) turns, and snugdown locknut. Repeat for all valves. Do not over tighten locknuts. This will prevent abent valve or push rod during installation of the rocker arm assembly.

NOTE: Bolts have 150 ft lbs of torque. Student using breaker bar will have another student behind him/her toguard against falls.

d. Using the 15\16" deep-well socket, 2" extension, and breaker bar, loosen the six (6)rocker arm assembly head bolts beginning from the center and moving alternately left

and right until all are loose. Utilize speeder wrench to free all bolts from threads butdo not remove bolts from assembly.

e. Place one hand under each end of the rocker arm shaft, lift up slightly, shakeassembly to ensure push rods do not stick to rocker arms, and then lift assembly outof cylinder head. Place assembly, with threaded ends of bolts pointed down, in valvecover. Cover assembly with rags.

2) Removal of Push Rods

a. Hold push rods in place and removes rags.

b. Push rods will be removed ONE at a time, IN ORDER from front to rear

c. Lift up slightly on push rod (approx. 1/2"), shake rod to insure it is not stuck to lifter,and lift out of engine.

d. Wipe off with rag and place in holed wooden block. Ensure rods are removed andplaced in wooden block in the proper order. Place rags back in cylinder head.

H. REMOVAL OF CYLINDER HEAD AND SPACER PLATE

1) Removal of Cylinder Head

a. Using the 15\16" deep well socket, 2" extension, and breaker bar, loosen the

remaining twenty (20) cylinder head bolts beginning from the center. Use a V or Wpattern moving alternately left and right away from center until all are loose. Utilizespeeder wrench to free all bolts from threads. As bolts and washers are removedplace them, head end first, in can marked HEAD BOLTS. Ensure washers remain onbolts.

b. Loosen the seven (7) air intake manifold head bolts using speeder wrench and 9/16socket. Start at center and work left to right until all are loose. Place, head end first,in can marked HEAD BOLTS.


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c. Remove air cleaner support bracket and place on shelf. Reinstall bolts and washerson cylinder head.

d. Screw two (2) eye bolts into threaded holes provided on opposite ends of cylinderhead. Recheck cylinder head to insure ALL head bolts have been removed.

e. Position hoist so that chain and hook at end of lifting beam is centered over cylinderhead. Attach lifting shackle to eye hooks on cylinder head and hook on lifting beam.Be careful not to strike cylinder head.

f. Pump handle to REMOVE SLACK from chains and recheck hoist to insure it iscentered over cylinder head.

g. One student will stand on each side of cylinder head with hands on TOP of cylinderhead and guide it as it is lifted. Instructor will operate hoist.

NOTE: Cylinder head weighs 142 lbs. Do not to place fingers or hands under cylinder head at any time for anyreason.

h. Raise cylinder head approximately 8" and wheel away from block. Students will

guide head to prevent it from swinging.

i. Wheel cylinder head to work bench and position it over two (2) wooden blocks placedat each end of head.

j. Students will guide cylinder head as it is slowly lowered onto wooden blocks. Ensureblocks are positioned so they don't rest on valves. Caution students once again tokeep hands and fingers from under cylinder head. Disconnect hoist and liftingshackle. Remove eyebolts and cover head with rags.

k. Remove head gasket from engine block at cylinder side being careful not to damagegasket. Wipe down and place behind cylinder head.

2) Removal of Cylinder Head Spacer Plate

a. Place small rags in holes in spacer plate that accommodate the push rods.

b. Remove ALL water seals and one (1) O-ring in spacer plate and place in can markedTAGS. Remove rags from holes in spacer plate.

c. Students will take hold of each end of spacer plate and lift it straight up from theblock. Wipe down spacer plate and place behind cylinder head.

d. Carefully remove spacer plate gasket from engine. Wipe down gasket and placegasket behind cylinder head.

e. Wipe down top of block. Cover top of block, spacer plate, andgaskets with rags. Police up area around engine.


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Title Reassemble a diesel engine.



NOTE: These procedures are based on the use of a CAT 3304 engine. Each school should adjust the proceduresto accommodate the engine being used.

Procedures:

1. REASSEMBLY OF ENGINE

A. INSTALLATION OF CYLINDER HEAD AND SPACER PLATE

1) Installation of Cylinder Head Spacer Plate

a. Thoroughly clean the spacer plate gasket, spacer plate, and cylinder block with cleanrags. Ensure all fluid is removed from head bolt holes in the block.

b. Install yellow o-ring on oil tube on top of cylinder block. Install spacer plate gasket oncylinder block, ensuring ALL holes in gasket are aligned with holes on cylinder block.

c. Install spacer plate on the cylinder block. Spacer plate must be lowered straightdown on the cylinder block.

d. Install yellow o-ring on oil tube on top of spacer plate. Install water seals inappropriate holes on spacer plate. Ensure smaller water seals ARE NOT placed incylinder head bolt holes on block (look for threads in holes before inserting seals).

2) Installation of Cylinder Head

NOTE: Ensure head gasket is aligned with the dowel pins in the engine block.

a. Install new head gasket on engine block, ensuring ALL holes in gasket are alignedwith holes on spacer plate.

b. Remove ALL rags from cylinder head and place them on the workbench. They will beused again once the cylinder head is back on the engine block.

NOTE: Cylinder head weighs 142 pounds.

c. Attach engine hoist to cylinder head. Lift cylinder head approximately 8 off theworkbench. Maneuver hoist and position cylinder head at rear of the engine.

d. Carefully wipe down the bottom of the cylinder head. Inspect the cylinder head toensure nothing is hanging below the bottom of the cylinder head.

NOTE: Foreign material caught between the cylinder head and engine block could cause serious damage toequipment.


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e. Push hoist forward and position cylinder head directly over engine block. Have two(2) students place their hands on the cylinder head to guide and support it as it islowered onto the engine block.

f. Slowly lower the cylinder head onto the engine block. Ensure students know to guidethe dowels at each end of the engine block into the appropriate holes on the bottomof the cylinder head.

NOTE: Ensure cylinder head is located on dowels.

g. Install 18 large cylinder head bolts and screw them in until they are hand tight. Install5 smaller intake manifold bolts and screw them in until they are hand tight.

h. Using rags removed from cylinder head before installation, cover/tie off all holes incylinder head.

i. Install air cleaner mounting bracket onto rear of cylinder head.

B. INSTALLATION OF PUSH RODS AND ROCKER ARM ASSEMBLY

1) Installation of Push Rods

a. Push rods will be installed ONE at a time, IN ORDER from the front of the engine tothe rear.

b. Remove rag from hole the push rod will go in. Remove push rod from wooden blockand wipe it down with a rag

c. Using a flashlight, guide the end of the push rod on to the TOP of the lifter it originallycame off of.

NOTE: Instructor will ensure that push rods are seated in lifters.

d. Once push rods are installed, place one rag in each hole the push rods are in toprevent items from falling into the engine.

2) Install Rocker Arm Assembly

a. Place one hand under each end of rocker arm shaft and remove it from valve cover.

b. Carry rocker arm assembly and place it directly over cylinder head. Ensure rockerarm bolts do not fall out of rocker arm bolt brackets.


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c. Ensure each rocker arm assembly bolt is in line with the appropriate bolt holes. Oncebolts are aligned with bolt holes, lower rocker arm assembly, making sure the rockerarms engage the valves and the push rods.

d. Once rocker arm assembly is in place and the rocker arms are engaged with the pushrods, screw in rocker arm assembly bolts until they are hand tight.

NOTE: Instructor will ensure that valve train mechanism is properly aligned.

3) Torque cylinder head bolts

a. Locate torque specifications and pattern in manual (SENR1189, pg 70). Instructstudents to become familiar with torque sequence.

NOTE: If head bolts are NOT torqued in sequence, possible engine damage could occur.

NOTE: Instructor will check the torque on each bolt after each tightening sequence. If any bolt in the sequenceis missed, students will loosen up ALL head bolts and start torque sequence from the beginning.

b. Tighten the head bolts in the numbered sequence to a torque of 115 lb ft.

c. Tighten the head bolts in the numbered sequence to a torque of 150 lb ft.

d. Tighten the head bolts in the numbered sequence to a torque of 150 lb ft.

e. Tighten the head bolts in the lettered sequence to a torque of 25 lb ft.

f. Once cylinder head is completely torqued, place the valve cover back on top of thecylinder head.

C. INSTALLATION OF EXHAUST SYSTEM COMPONENTS

1) Install Exhaust Manifold

a. Remove all rags from exhaust ports on cylinder head and exhaust manifold.

b. Clean all gasket surfaces around exhaust ports on cylinder head and exhaustmanifold.

c. Put new gaskets in position on studs, ensuring that the words THIS END OUT isfacing outward and is right-side up

NOTE: Hold exhaust manifold up against the cylinder head until washers and nuts are installed on the first and

last studs.

d. Put exhaust manifold in position on studs. Install washers and nuts on the first andlast studs. Tighten nuts until they are hand tight.

e. Install brackets between No. 1 and No. 2 cylinders and No. 3 and No. 4 cylinders withthe holes for bolts on top. Install the remainder of the washers and nuts.

f. Torque ALL manifold nuts to 25 lb ft.


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D. INSTALLATION OF FUEL SYSTEM COMPONENTS

NOTE: All personnel must wear safety goggles/glasses during fuel procedures. THIS INCLUDESINSTRUCTORS.

NOTE: There is the potential for fuel spillage during the next steps.

1) Timing of Fuel Injection Pump and Governor Assembly

a. Remove the bolts in the timing pin cover in position. Remove the cover and thegasket.

b. Install timing pin in to hole where cover was located. Timing pin will rest on fuelinjection pump camshaft.

c. Install the bolt that holds the fuel injection pump drive gear into the fuel injectionpump camshaft without the washer. This will allow the camshaft in the fuel system tobe turned.

d. Put pressure on the end of the timing pin and turn the camshaft slowly until the timingpin drops into the groove (slot) in the camshaft. The fuel injection pump is now set toinject fuel into the No. 1 cylinder.

NOTE: Ensure timing pin is NOT removed

e. Leave the timing pin in position in the groove (slot). Remove the bolt from the end ofthe camshaft. Place bolt back in FUEL INJ PUMP can.

2) Install the Fuel Injection Pump and Governor Assembly

NOTE: Ensure the engine is at top center (TC) compression position for NO. 1 piston.

a. Remove timing gear cover and rags covering holes.

b. Put clean engine oil on the O-ring seals (two on bottom and two on front).

c. Ensure the O-rings stay in place and position the fuel injection pump on the engine.Making sure the fuel injection pump camshaft slides into the hole in the fuel injectionpump drive gear.

d. Install the three (3) nuts on studs to hold the fuel injection pump to the engine. Installthe two (2) bolts that screw into the bottom of the fuel injection pump. Tighten allnuts and bolts until tight. DO NOT OVER-TIGHTEN.

e. Install bolt that secures fuel injection pump drive gear to fuel injection pump

camshaft. Torque bolt to 100 lb ft.

NOTE: Verify the bolt was torqued properly.

1) The following components/accessories must be installed after installing the Fuel Injection Pumpand Governor Assembly. Students in each group should work individually or in pairs toaccomplish these tasks.

a. Mount exhaust manifold heat shield and install two (2) bolts to secure exhaustmanifold heat shield to mounting brackets.


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b. Install tube between air inlet elbow and air/fuel ratio control. Only the end of the lineconnecting to the air/fuel ration control can be mounted. Tighten the fitting until linecannot be wiggled inside fitting. DO NOT OVER-TIGHTEN.

c. Connect two (2) wires to fuel shut-off solenoid. DO NOT OVER-TIGHTEN screws.Remove tags marking wires (if any).

d. Inspect the timing gear cover gasket and install timing gear cover. Tighten nuts in astar pattern (like lug nuts on a wheel). DO NOT OVER-TIGHTEN.

2) Installation of Fuel Filter and Supply / Return Lines

NOTE: There is the potential for fuel spillage during this section of engine assembly.

a. Clean rubber seal on fuel filter. Wipe down fuel filter base. Lubricate fuel filter sealwith a light coat of oil taken from the engine oil dipstick.

b. Install fuel filter by screwing it onto the fuel filter base. Once the fuel filter gasketmakes contact with the base, tighten the filter an additional 1/2 turn.

c. Install and tighten fuel inlet (between the primary filter and fuel transfer pump) andreturn fuel lines. DO NOT OVER-TIGHTEN.

3) Installation of Fuel Injection Lines

NOTE: There is the potential for fuel spillage during this section of engine assembly.

a. Remove caps/plugs from fuel injection lines and fuel injection valves.

b. Install fuel injection lines on engine as a unit. Install all fuel injection line nuts untilthey are finger tight.

c. Students will utilize 3/4" line wrench to tighten all fuel injection line nuts beginningwith No. 1 injector line at the fuel injection pump housing. Tighten all nuts on the fuelinjection pump from front to rear.

d. Tighten the fuel injection line nuts at the fuel injection valves working from front torear. Hold the top of each fuel injection valve with a 15/16 wrench and tighten fuelinjection line nuts with a 3/4" line wrench.

NOTE: Eye protection can be removed at this point.

E. ADJUSTMENT OF INTAKE AND EXHAUST VALVES

NOTE: Ensure engine is at Top Dead Center Compression Position for #1 Piston.

1) First Set of Intake and Exhaust Valves

a. Put No. 1 piston at top center (TC) on the compression stroke,

b. Make an adjustment to the valve clearance on the intake valves for cylinders 1 and 2.Use a thickness gauge to set clearance. Clearance will be set to 0.015. Clearancewill be checked with 0.017. 0.015 blade will drag slightly between the rocker armand the top of the valve. 0.017 blade will not pass through.


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c. Make an adjustment to the valve clearance on the exhaust valves for cylinders 1 and3. Use a thickness gauge to set clearance. Clearance will be set to 0.025.Clearance will be checked with 0.027. Use 0.013 and 0.014 blades to make0.027. 0.025 blade will drag slightly between the rocker arm and the top of thevalve. 0.027 blade will not pass through.

2) Second set of Intake and Exhaust Valves

a. Turn the flywheel 360 degrees in the direction of engine rotation. This will put No. 4piston at top center (TC) on the compression stroke.

b. Make an adjustment to the valve clearance on the intake valves for cylinders 3 and 4.Use a thickness gauge to set clearance. Clearance will be set to 0.015. Clearancewill be checked with 0.017. 0.015 blade will drag slightly between the rocker armand the top of the valve. 0.017 blade will not pass through.

c. Make an adjustment to the valve clearance on the exhaust valves for cylinders 2 and4. Use a thickness gauge to set clearance. Clearance will be set to 0.025.Clearance will be checked with 0.027. Use 0.013 and 0.014 blades to make

0.027. 0.025 blade will drag slightly between the rocker arm and the top of thevalve. 0.027 blade will not pass through.

d. After valve adjustments are correct, ensure the nuts for the valve adjustment screwsare tight.

F. INSTALLATION OF COOLING SYSTEM COMPONENTS

1) Installation of Water Temperature Regulator

a. Clean all contact surfaces

NOTE: If the water temperature is installed wrong, it will cause the engine to overheat.

b. Install temperature regulator into cylinder head.

c. Install new gasket, install regulator housing and 4 each mounting bolts

NOTE: Make sure the vent hole is open. The cylinder head can be damaged if the vent hole is not open or thegasket is installed wrong.

d. Tighten 4 each mounting bolts

e. Install top radiator hose and tighten clamps

2) Installation of water pump assembly

NOTE: There is a potential for anti-freeze/oil spillage during this portion of engine reassembly.

a. Clean all contact surfaces.

b. Install new o-ring on water pump.

c. Install new gasket on upper water pump elbow.


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d. Install water pump to water pump housing. Rotate bottom of water pump inwardtowards engine and seat pump into housing.

e. Install two (2) bolts into water pump housing. Install two (2) bolts into upper elbowhousing.

f. Alternately tighten all 4 water pump mounting bolts.

g. Connect oil cooler tube hose and tighten clamps.

h. Slide lower radiator hose up onto water pump and tighten clamps.

i. Connect water temp. sending unit to water pump.

j. Fill cooling system with proper coolant to the correct level.

NOTE: Instructor will check radiator

G. INSTALLATION OF AIR INDUCTION SYSTEM COMPONENTS

1) Installation of Turbocharger

a. Clean all contact surfaces.

b. Inspect all gaskets for damage and replace if necessary.

c. Install turbocharger on exhaust manifold. Ensure gasket between exhaust manifoldand turbocharger is positioned properly. Ensure the oil drain line is inserted prior toplacing the turbocharger directly on the manifold. Do not to pinch the O-ring on thedrain line during installation.

d. Install and tighten four (4) turbocharger mounting bolts.

NOTE: There is a potential for oil spillage during this portion of engine reassembly.

e. Install turbocharger oil inlet tube and tighten fitting and bolts. Make sure gasket inpositioned properly.

2) Installation of Exhaust Pipe

a. Remove coupling from can marked TURBO and inspect two (2) compression rings.Ensure slots in compression rings are not aligned.

b. Insert large end of coupling into exhaust pipe. Ensure coupling is fully seated inexhaust pipe. (Coupling is cast metal and may crack or break if dropped).

c. Position exhaust pipe/coupling assembly next to turbocharger on engine. Insert smallend of coupling into turbine side of turbocharger. Ensure coupling is fully seated.

d. Install two (2) nuts and bolts to secure exhaust pipe to exhaust manifold and tighten.

3) Installation of Air Inlet Elbow

a. Slide hose on inlet elbow into position on the turbocharger.


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b. Rotate inlet elbow so other end of elbow is in position on the cylinder head. Ensuregasket is in place and positioned properly.

c. Install and tighten four (4) bolts to secure inlet elbow to cylinder head. Tighten hoseclamps on hose connecting inlet elbow to turbocharger.

d. Connect tube from air/fuel ratio control to fitting on inlet elbow and tighten.

4) Installation of Air Filter Housing

a. Slide large hose on air filter housing tube onto inlet side of turbocharger and positionair filter housing on engine.

b. Install two (2) nuts and two (2) bolts holding air cleaner assembly to support bracketat rear of engine and tighten..

H. INSTALLATION OF ELECTRICAL SYSTEM COMPONENTS

1) Installation of Starter Motor

a. Remove engine turning tool group.

b. Clean all contact surfaces.

c. Install new gasket, if required.

d. Using a two-person lift, position starter motor into flywheel housing. One student willsupport the rear of the starter while another installs and tightens three (3) startermounting bolts.

e. Identify and connect all electrical connections.

2) Installation of Alternator

a. Slide alternator into position on engine.

b. Install lower mounting bolt and spacer.

c. Install upper adjusting bolt and spacer.

d. Slide alternator inward to engine and install alternator belts.

e. Adjust alternator belts in accordance with technical manual procedures.

f. Connect alternator wires.

B. BLEEDING THE FUEL SYSTEM

1) To bleed the fuel system of air, pump the hand priming pump and open the drain valve on thefuel injection pump housing until fuel without air comes from the drain valve.

2) To remove air from the fuel injection lines, pump the hand primer pump until the fuel pressuregauge reads completely in the green zone.


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NOTE: When the fuel injection lines are loosened or tightened on the fuel injection valves, two wrenches mustbe used. The fuel injection valve must be held in place with a wrench or damage to the fuel injectionnozzle will result.

3) Loosen the fuel line nuts at the fuel injection valves, one at a time, from front to rear, until fuelwithout air comes from the fuel injection line nut. Tighten the fuel injection line nut after the airis bled from the line.

C. PERFORM PRE-OPERATION CHECKS

NOTE: There is a potential for fuel, oil, and anti-freeze spillage during this section of engine reassembly.

1) Ensure cooling system is filled as specified

2) Ensure engine oil level is to specification

3) Connect batteries

NOTE: Student must wear eye protection while connecting batteries.

4) Check all hoses, clamps, tube fittings and electrical connections for tightness

5) Ensure drive belts are adjusted properly

D. ENGINE STARTING PROCEDURES

1) Turn on fuel supply

2) Ensure all personnel are clear of the engine and are wearing eye and hearing protection

3) Ensure fuel lever is in the idle position

4) Press start and allow engine to idle

NOTE: If engine does not start, perform troubleshooting and corrective actions until engine starts.

E. DURING OPERATION CHECKS

NOTE: Do not remove radiator cap while the engine is hot and the cooling system is under pressure. Letengine cool before removing fill cap from radiator. Loosen the filler cap to the first stop and let thepressure out of the cooling system, then remove the filler cap. Hot coolant and steam can causepersonal injury.

1) Cooling System: The cooling system should be checked for proper operation and condition.The radiator should be checked for leaks, worn hoses, and trash buildup.

2) Fuel System: The fuel system should also be checked for proper operation and condition.Check fuel lines and also the fuel filter housings for cracks. Cracks may cause leaks. Tightenor replace all lines and hoses that leak.

3) Lubricate System: Check for proper operation and condition of the lubrication system. Thereshould be no leaks. Inspect all oil lines and hoses for cracks, frays and wear that could causeleaks. Tighten or replace all lines and hoses that leak.


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4) Intake System: Check for the proper operation and condition of the intake system. Ensure thatthe air cleaner screen is in place to prevent foreign objects from entering the system. Also,check the operation of the turbocharger for proper operation and any oil leaks.

5) Exhaust System: Check for the proper operation and condition of the exhaust system. Lookfor any exhaust leaks that may cause a safety deficiency/deadline.

F. ENGINE SHUTDOWN PROCEDURES

1) Push fuel lever to off position

2) Shut-off fuel supply valve

3) Disconnect batteries


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Title Implement diagnostic test and adjustment procedures on diesel engines andcomponents.



Student Materials:

Student Study Guide

Equipment manuals extracts

Practical exercise sheets

Eye Protection

Hearing Protection

Coveralls

Procedures:

Station #1

At this station, you have a two-stroke or four-stroke diesel engine, TMDE, and the applicable TMs and references. Yoursupervisor informs you that the engine has a problem in the air induction system. Perform all steps and tests to verify theair induction system is operating properly. After checking the system, if you do not find any faults, report your findings tothe instructor. Record the findings of the tests performed on the DA Form 5988E.

Station #2

At this station, you have a two-stroke or four-stroke diesel engine, TMDE, and the applicable TMs and references. Your

supervisor informs you that the engine has a problem in the fuel system. Perform all steps and tests to verify the fuelsystem is operating properly. After checking the system, if you do not find any faults, report your findings to the instructor.Record the findings of the tests performed on the DA Form 5988E.

Station #3

At this station, you have a two-stroke or four-stroke diesel engine, TMDE, and the applicable TMs and references. Yoursupervisor informs you that the engine has a problem in the lubrication system. Perform all steps and tests to verify thelubrication system is operating properly. After checking the system, if you do not find any faults, report your findings to theinstructor. Record the findings of the tests performed on the DA Form 5988E.

Station #4

At this station, you have a two-stroke or four-stroke diesel engine, TMDE, and the applicable TMs and references. Yoursupervisor informs you that the engine has a problem in the cooling system. Perform all steps and tests to verify thecooling system is operating properly. After checking the system, if you do not find any faults, report your findings to theinstructor. Record the findings of the tests performed on the DA Form 5988E.

Station #5


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At this station, you have a four-stroke diesel engine, TMDE, and the applicable TMs and references. Your supervisorinforms you that the engine runs rough. Using the applicable TMs and references, check the engine to correct themalfunction. Perform all the steps and tests to verify that the engine is operational. After checking the system, if you donot find any faults, report your findings to the instructor.

Station #6

At this station, you have a four-stroke diesel engine, TMDE, and the applicable TMs and references. Your supervisorinforms you that the engine lacks power. Using the applicable TMs and references, check the engine to correct themalfunction. Perform all the steps and tests to verify that the engine is operational. After checking the engine, if you donot find any faults, report your findings to the instructor.


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HYDRAULIC SYSTEMS

PRACTICAL EXERCISE SHEET 62B10D01PE1

Title Repair and replace a hydraulic cylinder.


62B10D01 version ADT / Hydraulic Systems

Student Materials:

Eye Protection

Safety Boots

Coveralls

TM 5-2350-262-34

TM 5-3805-262-20

Procedures:

Problem One: Replace a hydraulic cylinder.

At this station you are in an Organizational Maintenance environment. You have a MW24C Scoop Loader. Yoursupervisor has told you to replace the bucket clamshell cylinders. Using applicable TMs and tools remove and replace thebucket clamshell cylinders. Follow all safety procedures and insure you are wearing eye protection, coveralls and safetyboots.

Hydraulic Cylinder Removal

NOTE: Plug or cap lines disconnected or removed and plug clam cylinder assembly ports in the following stepsto prevent foreign matter from entering the hydraulic system.

1. Tag, disconnect, and remove lines from cylinder assembly ports.

2. At top of cylinder assembly, remove locknut and cap screw.

3. Using a hammer and a brass drift, drive pin from cylinder rod eye.

4. At the bottom of cylinder assembly, loosen and remove lock nut and cap-screw

5. Using hammer and a brass drift, drive pin out of cylinder tube yoke.

6. Remove clam cylinder assembly from bucket.


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Installation

1. Position clam cylinder assembly on rear of bucket.

2. Align cylinder tube yoke hole at bottom of cylinder with pivot hole in bucket.

3. Start pin into pivot hole at bottom of cylinder; be sure hole in pin is aligned with hole in cylinder.

4. Remove plugs and reconnect lines to cylinder assembly ports.

5. Using hammer and a brass drift drive pin into place at the bottom of the cylinder.

6. Install and tighten cap screw and lock nut at the bottom of the cylinder.


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Problem Two: Repair a hydraulic cylinder.

At this station you have a hydraulic cylinder from an item of construction equipment that was removed by anothermechanic. You have been instructed by your supervisor to repair the cylinder and bring the equipment back to operationalstatus. Follow all safety procedures and insure you are wearing eye protection, coveralls and safety boots.

Cylinder Disassembly

1. Remove two plugs from oil ports.

2. Remove set screw from cylinder housing.

3. Unscrew cylinder head by turning counterclockwise using spanner wrench.

NOTE: Use two personnel when removing piston rod from housing.

4. Remove piston rod from cylinder housing and place on the bench.

5. Remove cylinder housing from vise and place it on the floor in front of the bench.

6. Place the yoke of the piston rod in the vice, with the piston facing inward.

7. Remove piston locknut using 3\4 drive socket.

8. Remove piston from piston rod.

NOTE: Use caution when removing cylinder head. Threads are sharp and will cut you.

9. Remove cylinder head from the piston rod (lubricate piston rod if needed).

Seal removal

1. Remove two wear rings from the piston.

2. Remove the packing and the retainer from the cylinder head.

Cylinder Assembly

1. Replace all seals

2. Install cylinder head on piston rod with wiper seal facing yoke. (Use care not to mar or scratch rod duringinstallation)

3. Install piston onto the piston rod with open end of piston facing the piston rod threads.

4. Install piston locknut on piston rod and tighten nut with 3\4 drive socket.

5. Remove piston rod from the vise.

6. Place cylinder in the vice and install piston rod.

7. Using spanner wrench install cylinder head into the cylinder.(ensure chalk marks are lined up


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NOTE: Normally the setscrew would be replaced with a new one but for training purpose the same one is used.

8. Secure cylinder head into cylinder with setscrew.

9. Install two caps into oil ports.


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Title Interpret hydraulic schematics.

Lesson Number / Title 62B10D01 version ADT / Hydrau

Resource Requirements Instructor Materials:

Vickers Hydraulics Manual

Student Materials:

Color markers

Hydraulic simulator boards

Student guides

Vickers Industrial Hydraulics Manual inserts

Pens and pencils

Procedures:

Problem #1: Retract circuit.


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RETRACT

#5

#9

#12

#11

#10

500 PSI


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Problem #2: Retract at controlled speed circuit.

RETRACT AT CONTROLLED SPEED

#5

#9

#12

#11

#10

#12

#3

500 PSI


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Problem #3: Sequencing circuit extending.

SEQUENCING CIRCUIT

#12

#5

#9

#11

#10

#

#2

500 PSI

300 PSI


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Problem #4: Pressure reducing circuit extending.

PRESSURE REDUCING CIRCUIT

#5

#9

#11

#10

#2

#12 #4

500 PSI

200 PSI

#12


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Problem #5: Rotary drive with speed control.

ROTARY DRIVE WITH SPEED CONTROL

#9

#12

#11

#10#3

#8

500 PSI


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Quiz.

200 PSI

# 4

# 12A

# 9

# 10

NAME Students #


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1. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER FOUR?

1. PRESSURE SEQUENCE VALVE2. PRESSURE RELIEF VALVE3. PRESSURE REDUCING VALVE4. PRESSURE UNLOADING VALVE

2. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER ELEVEN?


3. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER SIX?


4. WHAT TYPE OF CONTROL VALVE IS VALVE NUMBER NINE?

1. PRESSURE CONTROL2. DIRECTION CONTROL3. VOLUME CONTROL4. SOLENOID CONTROL

5. WHAT IS THE MAX PRESSURE READING GAUGE NUMBER 12B WILL READ WHEN THECYLINDERS ARE FULLY EXTENDED?

1. 300 PSI2. 500 PSI

3. 200 PSI4. 0 PSI

6. WHAT IS THE MAX PRESSURE READING GAUGE NUMBER 12A WILL READ WHEN THECYLINDERS ARE FULLY EXTENDED?

1. 300 PSI2. 500 PSI3. 200 PSI4. 0 PSI

7. WHAT IS THE PRESSURE READING AT GAUGE12B WHILE CYLINDER TWO IS EXTENDING?

1. 300 PSI2. 500 PSI3. 200 PSI4. 0 PSI

8. WHICH CYLINDER WILL EXTEND FIRST?

1. CYLINDER NUMBER TWO2. CYLINDER NUMBER FIVE3. BOTH CYLINDERS AT THE SAME TIME


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4. NEITHER CYLINDER WILL EXTEND

9. WHAT COMPONENT IS ITEM NUMBER TEN?

1. UNIDIRECTIONAL MOTOR2. VARIABLE DISPLACEMENT PUMP3. FIXED DISPLACEMENT MOTOR4. FIXED DISPLACEMENT PUMP

10. WHAT TYPE OF RESERVOIR IS SHOWN?

1. PRESSURIZED2. OPEN3. VENTED4. CLOSED

11. WHAT TYPE OF CYLINDER IS CYLINDER NUMBER FIVE?

1. VAIN TYPE2. SINGLE ACTING PISTON

3. DOUBLE ACTING BALANCED4. DOUBLE ACTING UNBALANCED

12. VALVE NUMBER FOUR HAS A DASHED LINE THAT GOES TO A RESERVOIR SYMBOL, THISLINE IS A?

1. COMPONENT LINE2. PILOT LINE3. RETURN LINE4. DRAIN LINE

13. VALVE NUMBER FOUR HAS A DOTTED LINE THAT GOES TO AN ENVELOP THIS LINEREPRESENTS A?

1. COMPONENT LINE2. PILOT LINE3. RETURN LINE4. DRAIN LINE

14. HOW MANY POSITIONS DOES THE DIRECTIONAL CONTROL VALVE HAVE?

1. SIX2. THREE

3. FIVE4. FOUR

15. A DOTTED BOX AROUND VALVE NUMBER SIX REPRESENTS A?

1. CONTROL VALVE2. TWO ITEMS IN ONE VALVE3. COMPONENT ENCLOSURE4. PILOT OPERATED POPPET VALVE


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Title Charge an Accumulator.

Student Materials:

Actuator Accumulators

Charging Device with nitrogen

TMDE

General mechanics tool kit

Special tools

Eye Protection

Coveralls

Student guide

Procedures

1. Follow the steps in the TM.

2. Insure all safety procedures are followed and eye protection and coveralls are worn.

a. Disregard the highlighted areas. Instructor will explain.

b. Instructor will provide students with the temperature.

c. Instructor will assist students as needed.


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Title Replace, Test, and Adjust Hydraulic Control Valves and Pumps.


62B10D01 version ADT / Hydraulic Systems

Procedures

1. Problem #1: Backhoe/crane pressure relief valve cannot be adjusted on the FLU 419 (SEE)

At this station you are in a Direct Support Maintenance environment. You have aFLU 419 (SEE). Your Maintenance chief/ Supervisor has provided you with a newbackhoe/crane pressure relief valve and instructed you to replace it. After youreplaced the valve you operated the equipment and the backhoe would not go into orout of transport position. You have TMDE, special tools and all applicable TMs.Follow all safety procedures and wear eye protection and coveralls. Using theapplicable TMs, replace the backhoe/crane pressure relief valve. Connect theappropriate test equipment to the item of equipment with the appropriate connector(s)and adjust the valve. Isolate the malfunction using the referenced diagnostic tests.

When the malfunction has been correctly diagnosed, take the appropriate action tocorrect it.

2. Problem #2: The compensating pump drive shaft is broken on the M9 ACE.

At this station you are in an Organizational Maintenance environment. Yoursupervisor tells you to remove the old pump and replace it. You have TMDE, specialtools and all applicable TMs. Follow all safety procedures and wear eye protectionand coveralls. Using the applicable TMs; Replace the pump, connect the appropriatetest equipment to the item of equipment with the appropriate connector(s) and adjustthe pump.

3. Problem #3: Slow or hard steering on the MW 24C (LOADER).

At this station you are in a Direct Support Maintenance environment. You have aMW 24 C LOADER with slow or hard steering, TMDE, and special tools with allapplicable TMs and necessary maintenance forms. Follow all safety procedures andwear eye protection and coveralls. Using the applicable TMs, connect theappropriate test equipment to the item of equipment with the appropriateconnector(s). Isolate the malfunction using the referenced diagnostic tests. Whenthe malfunction has been correctly diagnosed, take the appropriate action to correctit.

4. Problem #4: The hydraulic system not functioning properly C130 (GRADER).

At this station you are in an Organizational Maintenance environment. You have a C130 Grader with the hydraulic system not functioning properly, TMDE, and specialtools with all applicable TMs. Follow all safety procedures and wear eye protectionand coveralls. Using the applicable TMs, connect the appropriate test equipment tothe item of equipment with the appropriate connector(s). Isolate the malfunctionusing the referenced diagnostic tests. When the malfunction has been correctlydiagnosed, take the appropriate action to correct it.


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POWER TRAIN SYSTEMS

PRACTICAL EXERCISE SHEET 62B10E01 PE1

Title Perform Power Shift Transmission Troubleshooting, Repair, and Adjustments


62B10E01 version ADT / Power Train Systems

Student Materials:

TM 5-2350-262-20-1TM 5-2350-262-20-2TM 5-2410-237-20TM 5-2410-237-34TM 5-3805-248-14P-2TM 5-3805-262-20

TM 5-3805-262-24PTM 5-3805-262-34TM 9-214TM 9-4910-571-12&PTM 9-8000LO 5-3805-261-12Eye ProtectionHearing ProtectionSafety BootsStudent guides

Pens and pencils

Procedures

Station #1:

At this station you have a 621B scraper that is not shifting properly. Locate in TM 5-3805-248-14&P-2,Testing and Adjusting, pg. 2-33 the fault transmission does not make a shift and inform the instructor ofthe first probable cause.

When told to do so perform the test with TMDE provided.

Check the governor oil pressure IAW TM 5-3805-248-14&P2 and test #50 IAW TM 9-4910-571-12&P.

Inform the instructor of the results.

Shut down and disconnect TMDE when told to do so.


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Station #2:

At this station you have a MW24C Scoop Loader that has slow or erratic transmission shifting. Using TM5-3805-262-20 locate "Troubleshooting". Under "Transmission", locate "Slow or erratic transmissionshifting".

When told to do so perform steps #1 through #3 IAW the TM troubleshooting guide.

Inform the instructor of the requirements for step #4 IAW the TM troubleshooting guide.

Answer the instructors questions and wait for further guidance.

Using TM 5-3805-262-34 locate "Troubleshooting". Under "Transmission", locate "Slow or erratictransmission shifting".

Inform the instructor of the steps to follow IAW the TM troubleshooting guide.

When told to do so perform the test with TMDE Provided.

Check the transmission oil pressure IAW TM 5-3805-262-34 and test #50 IAW TM 9-4910-571-12&P.

Annotate all readings using the example below:

Position Book Results Actual ResultsN 135 psi.

R 135 psi.

F 135 psi.

H 125-132 psi.

Inform instructor of the results.



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Station #3:

At this station you have D7G Bulldozer that MOVES IN FORWARD SPEEDS ONLY. Using TM 5-2410-237-34 locate "Troubleshooting". Under "Symptom Index", locate UNDER TRANSMISSIONTROUBLESHOOTING TRACTOR MOVES IN FORWARD SPEEDS ONLY".

Inform the instructor of the steps to follow IAW the TM troubleshooting guide.

When told to do so perform Students will check the transmission shift lever adjustment and adjust ifneeded.

Perform a transmission pump test using the TMDE supplied

Check the transmission oil pump pressure IAW TM 5-2410-237-34 and test #50 IAW TM 9-4910-571-12&P.

Inform instructor of the results.



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Station #4:

At this station you have D7G Power Shift Transmission. Using TM 5-2410-237-locate pages 7-7"Transmission Assembly Maintenance Replace/Repair".

Start at step 24 and disassemble the transmission down to clutch pack number 5 (Do not disassemble theplanetary gears.)

Page 7-43; Inspect the clutch plates according to the technical manual

Page 7-51; Reassemble transmission.

After reassembly, have students identify clutch packs.

NOTE: The two front clutches (No.1 and No.2) are direction clutches. The No.1 clutch is theforward clutch. The No.2 clutch is the reverse direction clutch. The three rear clutches (No.3,No.4 and No.5) are the speed clutches.

SPEED CLUTCHES ENGAGED

First Forward 1 and 5

Second Forward 1 and 3

Third Forward 1 and 4

First Reverse 2 and 5

Second Reverse 2 and 3

Third Reverse 2 and 4


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Title Identify differential and axle components and their functions.



Procedures:

Station #1

At this station you have an MW24C loader with excessive drive shaft (propeller) vibration of the front driveshaft. Using TM 5-3805-262-20 determine and correct the fault.

Locate "Troubleshooting", and then locate "Excessive Drive Shaft Vibration".

When told to do so perform steps #1 through #5 IAW the TM troubleshooting guide.


Using TM 5-3805-262-34, locate "Troubleshooting" and then locate "Excessive Drive Shaft Vibration".

When told to do so perform steps #1 through #3 for the front axle IAW the TM troubleshooting guide.

When told to do so perform steps #1 through #3 for the rear axle IAW the TM troubleshooting guide.

Inform the instructor of the results.

Station #2:

At this station you have an axle assembly. Following the instructors guidance, you are to remove an axleshaft, final drive and differential, inspect them per the instructors guidance and replace them.

Station #3:

At this station you have an M9ACE with excessive noise or vibration and excessive engine vibration.Using TM 5-2350-262-20-1 and TM 5-2350-262-20-2 determine and correct the faults.

Locate "Troubleshooting" in TM 5-2350-262-20-1 and then locate "Excessive Noise or Vibration" or"Engine Vibrates Excessively".

When told to do so perform steps #1 and #2 IAW the TM troubleshooting guide.

Inform instructor what further steps the TM troubleshooting guide leads you to.



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Title Identify final drive components and their functions.



Student Materials:

TM 5-2350-262-20-1TM 5-2350-262-20-2TM 5-2410-237-20TM 5-2410-237-34TM 5-3805-248-14P-2TM 5-3805-262-20TM 5-3805-262-24PTM 5-3805-262-34TM 9-214TM 9-4910-571-12&PTM 9-8000

LO 5-3805-261-12Student guidesPens and pencils

Eye & Hearing Protection

Safety Boots

Coveralls

Work Gloves

Procedures

Station #1:

At this station you have a 621B Scraper. Using TM 5-3805-248-14&P2 and following the instructorsguidance, you will remove, disassemble, inspect, reassemble and replace the final drive assembly.

Station #2a:

At this station you have a D7G tractor, Full Tracked. Using TM 5-3805-237-20 and following theinstructor's guidance, you will perform a track, steering brake and steering clutch linkage adjustment.

Station #2b:

At this station you have a D7G tractor, Full Tracked. Using TM 5-3805-237-20 and following the

instructor's guidance, you will repair a winch brake.

Station #3:

At this station you have a final drive M9Ace Mock-Up. Following the instructors guidance and TM 5-2350-262-20-1 and 2 you will disconnect and reconnect the final drive assembly.


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Station #4a:

At this station you have an M9 ACE with an unserviceable track component. You are to replace theunserviceable track component (IAW) TM 5-2350-262-20-2 and follow all warnings and instructorsguidance. You will also remove, classify, and replace a road wheel IAW TM 5-2350-262-20-2.

NOTE: Instructor will inform students which road wheel will be removed.

Station #4b:

At this station you have an M9 ACE with an unserviceable track. You are to replace the unserviceabletrack (IAW) TM 5-2350-262-20-2 and follow all warnings and instructors guidance.


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BRAKE SYSTEMS

PRACTICAL EXERCISE SHEET 62B10F01PE1

Title Correct an Air Brake System Malfuncti

Lesson Number / Title 62B10F01 version ADT / Brake System


Student Materials:

TM 5-3805-248-14&P1

TM 5-3805-248-14&P2

TM 5-3805-248-14&P3

TM 5-3805-248-14&P4

TM 5-3805-262-20

TM 5-3805-262-34

TM 5-3805-261-34

TM 9-2320-211-20 w/ch 1-3

TM 9-2320-211-20-1 w/ch 1

TM 9-2320-211-20-2-1 w/ ch 1

TM 9-2320-211-20-2-2

TM 9-2320-211-20-3 w/ch 1

TM 9-2320-211-20-3-2

TM 9-8000

Student guides

Petroleum oil and lubricants

Necessary maintenance forms

Pens and pencils

PPE

Practical Exercise #1, Problem #1:

At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with low air pressure, TMDE, special tools, all applicable TMs, and necessary maintenanceforms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment withthe appropriate connector(s). Isolate the malfunction using the referenced diagnostic tests. When themalfunction has been correctly diagnosed, take the appropriate action to correct it. Major equipment

components and assemblies will not be dismantled. Malfunctions of major components will be correctlyannotated on the necessary maintenance forms.


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At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with high air pressure, TMDE, special tools, all applicable TMs, and necessary maintenanceforms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment withthe appropriate connector(s). Isolate the malfunction using the referenced diagnostic tests. When themalfunction has been correctly diagnosed, take the appropriate action to correct it. Major equipmentcomponents and assemblies will not be dismantled. Malfunctions of major components will be correctlyannotated on the necessary maintenance forms.


At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with decreasing air pressure, TMDE, special tools, all applicable TMs and necessarymaintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item ofequipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostictests. When the malfunction has been correctly diagnosed, take the appropriate action to correct it.Major equipment components and assemblies will not be dismantled. Malfunctions of major componentswill be correctly annotated on the necessary maintenance forms.


At this station you have an item of construction equipment with not enough difference between cut-in andcut-out pressure, TMDE, special tools, all applicable TMs, and necessary maintenance forms. Using theapplicable TMs, connect the appropriate test equipment to the item of equipment with the appropriateconnector(s). Isolate the malfunction using the referenced diagnostic tests. When the malfunction hasbeen correctly diagnosed, take the appropriate action to correct it. Major equipment components andassemblies will not be dismantled. Malfunctions of major components will be correctly annotated on thenecessary maintenance forms.


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Title Correct a Hydraulic Brake System Mal



TM 5-3805-248-14&P1

Student Materials:

TM 5-3805-248-14&P1

TM 5-3805-248-14&P2

TM 5-3805-248-14&P3

TM 5-3805-248-14&P4

TM 5-3805-262-20

TM 5-3805-262-34

TM 5-3805-261-34

TM 9-2320-211-20 w/ch 1-3

TM 9-2320-211-20-1 w/ch 1

TM 9-2320-211-20-2-1 w/ ch 1

TM 9-2320-211-20-2-2

TM 9-2320-211-20-3 w/ch 1

TM 9-2320-211-20-3-2

TM 9-8000

Student guides


Pens and pencils

Procedures:


At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with air in the hydraulic brake lines, special tools, all applicable TMs, and necessarymaintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item ofequipment with the appropriate connector(s). Isolate the malfunction using the correct referenceddiagnostic tests. When the malfunction has been correctly diagnosed, take the appropriate action to

correct it. Major equipment components and assemblies will not be dismantled. Malfunctions of majorcomponents will be correctly annotated on the necessary maintenance forms.


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At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with a faulty hydraulic brake master cylinder, special tools, all applicable TMs, and necessarymaintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item ofequipment with the appropriate connector(s). Isolate the malfunction using the recommended referenceddiagnostic tests. When the malfunction has been correctly diagnosed, take the appropriate action tocorrect it. Major equipment components and assemblies will not be dismantled. Malfunctions of majorcomponents will be correctly annotated on the necessary maintenance forms.


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Title Correct Assisted Brake System Malfun



TM 5-3805-248-14&P1

Student Materials:

TM 5-3805-248-14&P1

TM 5-3805-248-14&P2

TM 5-3805-248-14&P3

TM 5-3805-248-14&P4

TM 5-3805-262-20

TM 5-3805-262-34

TM 5-3805-261-34

TM 9-2320-211-20 w/ch 1-3

TM 9-2320-211-20-1 w/ch 1

TM 9-2320-211-20-2-1 w/ ch 1

TM 9-2320-211-20-2-2

TM 9-2320-211-20-3 w/ch 1

TM 9-2320-211-20-3-2

TM 9-8000

Student guides

Petroleum oil and lubricants


Pens and pencils

Hearing Protection

Eye Protection

Coveralls

Rubber gloves

Work gloves

Procedures:


At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with uneven or erratic service brakes, special tools, all applicable TMs, and necessarymaintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item ofequipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostictests. When the malfunction has been correctly diagnosed, take the appropriate action to correct it.Major equipment components and assemblies will not be dismantled. Malfunctions of major componentswill be correctly annotated on the necessary maintenance forms.


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At this station you are in an Organizational Maintenance environment. You have an item of constructionequipment with poor braking action, special tools, all applicable TMs, and necessary maintenance forms.Using the applicable TMs, connect the appropriate test equipment to the item of equipment with theappropriate connector(

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