2005 Us Army Construction Equipment Repairer Instructor's Guide 193p

62B10 (R) ADT, PHASE 2 CONSTRUCTION EQUIPMENT REPAIRER INSTRUCTOR'S GUIDE
SHOP OPERATIONS
PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 2: 62B10A02 version ADT PRACTICAL EXERCISE SHEET 62B10A07PE1
Title Lesson Number / Title
Proper Use of Tools. 62B10A02 version ADT / Employ Test, Measurement and Diagnostic Equipment (TMDE), general mechanics and special tools.
Introduction Motivator
To become a successful Construction Equipment Repairer you must be able to identify and utilize a variety of tools and Test, Measurement and Diagnostic Equipment (TMDE). Without this knowledge you risk damaging tools, TMDE, equipment and possibly injuring personnel.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 2) At the completion of this lesson, you [the student] will: Action: Employ tools.
Learning Step/Activity
Safety Requirements
The use of Personal protective Equipment (PPE) by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low - Review the deliberate risk assessment, perform a daily risk assessment, ensure it is recorded on appropriate forms, signed by authorized command authority, and posted at the training site(s). No major environmental impact, training entirely of an administrative or classroom nature, with little or no environmental impact on the environment, equipment or personnel
Risk Assessment
Environmental Considerations
Evaluation Instructional Lead-In
Inform students of the Terminal Learning Objective (TLO) requirements. State the complete action, condition, standards safety, risk assessment level and environmental considerations. Explain the importance of being able to identify and safely use and care for tools. NOTE: Introduce the lessons topic to be discussed.
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1. 2.
Resource Requirements InsItructor r Materials: I
A demonstration of the proper use of tools and an explanation of safety precautions. A practical exercise on the proper use of tools.
LocalSOP(s)
Instructor Materials: TM 9-243 SC 5180-90-N26 Local SOPs
Student Materials:
Student guides Pens and pencils
Special Instructions
Instructor Guidance a. Ensure each station has the applicable manufacturers reference as required. b. Ensure all PPE is available at each station. c. Ensure all required tools are available at the pertinent station.
d. Verify all students have removed all jewelry prior to beginning the PE. e. Ensure each station has a copy of each practical exercise sheet and a TM 9-243. f. Assist students as required. g. Five minutes prior to the PE ending, stop and answer any questions the students may have. Determine if students have learned the material presented by: (a) (b) (c) Soliciting student questions and explanations. Asking questions and receiving answers from the students. Correcting student misunderstandings.
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Explain to students: a. Inform students of the amount of time allocated for this PE. b. The practical exercise will consist of four stations. c The class will be divided among three of the four stations.
d. You cannot go to station two prior to completing station one. e. Breaks will be taken as required to use the restroom. f. You must use TM 9-243 and follow the instructors guidance at each station.
g. Safety equipment will be worn at each station. h. Remove all jewelry. If you have a wedding band that cannot be removed, inform me so it can be taped up. i. If you have any problem, raise your hand for assistance from an instructor.
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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 the instructor, 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.
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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. 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 from the 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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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10A07PE1 Station One: Solution: The Student: 1. Used the TM to reference the proper use of the tools prior to beginning work. 2. Properly installed the blade in the hacksaw, teeth forward. 3. Properly secured the metal in the vice and cut the round stock and bar stock to the specified length. 4. Used the correct file and removed any rough edges or burrs from both items of metal. 5. Used the center punch to mark the bar stock for drilling. NOTE: The student must be wearing safety goggles. 6. Selected the correct drill twist size. NOTE: The drill must be unplugged when the student is installing or removing the drill twist from the drill. 7. Installed and secured the drill twist into the drill properly. 8. Properly drilled the hole without causing damage to the equipment or personal injury. 9. Used the file to remove any burrs or rough edges as required. 10. Removed the drill twist from the drill and placed it back in the set. Station Two: Solution: The student:
1. Used the TM for all of the following steps. 2. Properly positioned and secured the metal in the vice. 3. Selected the proper tap and die from the sets. 4. Inspected the items for defects or breakage. 5. Properly inserted the tap in the tap wrench. 6. Properly used the tap to cut internal threads in the piece of flat stock. 7. Properly used the die to thread the round stock. 8. Attached the threaded round stock to the threaded square stock. 9. Cleaned lubricated and returned the components to their sets. Station Three: Solution: The student:
1. Used the TM. 2. Inspected the tools for damage or serviceability. 3. Selected the proper size die block. 4. Used the tube cutter to properly cut a specified length of tubing. 5. Properly used the reamer to remove any burrs from cutting.
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6. Properly positioned the tubing in the die block. 7. Performed a single flare IAW the TM. 8. Turned the piece of tubing over and repeated steps # 5 and 6. 9. Selected the proper adapter and made a double flare to the tubing. 9. Inspected the flares for breakage or cracks. 10. Re-flared the tubing if it was cracked or broken. 11. Cleaned and secured all tools when the exercise was complete. Station Four: Solution: The student: 1. Used torque specifications from a TM. 2. Explained the process as the TM prescribes it. 3. Include incremental step torque procedures.
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ELECTRICAL SYSTEMS
PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10B01 version ADT PRACTICAL EXERCISE SHEET 62B10B01PE 1
Title Lesson Number / Title Introduction Motivator
Identify Wiring Schematics 62B10B01 version ADT / Electrical Systems
Explain the importance of being able to properly id schematics and electrical symbols to the item of eq
NOTE: The instructor should inform the students of the requirements. (TLO Step 2) At the completion of this lesson, you [the student] will: Action: Identify wiring schematics.
Safety Requirements
There are no safety considerations associated with
Safety alerts, warnings, and reinforcements will be points in the lesson where safety issues arise.
Risk Assessment
Low - Review the deliberate risk assessment, perf ensure it is recorded on appropriate forms, signed authority, and posted at the training site(s).
No major environmental impact, training entirely of nature, with little or no environmental impact on the personnel. Practical Exercise State the complete, safety, risk assessment level, considerations.
Resource Requirements
Instructor Materials:
* TC 9-60 * * * * * * * * * * * 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
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* TM 9-6140-200-14 * TM 9-8000 * TM 11-6625-3199-14 * FOS 20 * ITRO-B TSP * Wiring schematics
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
Before presenting this lesson, Divide class in to tw
1. Group #1 will do a PE on learning activity #
3. After 1 hour the groups will switch for an a
4. Ensure all materials are on hand and in qu
Read and understand B01 TSP prior to conduc
1. Ensure that students have a study g MW24C scoop loader and three c 2. Explain to students:
a. Each student is to work individuall
b. Fifteen minutes will be allotted for Exercise. c.
Following Problem #1, five minute solution with the instructor.
d. Fifteen minutes will be allotted for
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Exercise.
e. Following Problem #2, five minute instructor to review the solution. f.
Fifteen minutes will be allotted for Exercise. Following Problem #3, fi the instructor to review the solutio
Assist students as required.
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Procedures
Identify Wiring Schematics: Problem #1: 1) 2) 3) 4) 5) 6) 7) 8) 9) Using the MW24C Scoop Loader schematic and the study guide identify either a symbol or a component as required.
Locate the fixed resistor in front of the clutch pressure switch. Locate the variable resistor at the water temperature sender. Located the single pole/single throw switch in the upper cab. Locate the N. O. cab relay in the engine compartment. Locate the 30-amp circuit breaker above the cab relay. Locate the single filament bulb at the rear flood lamp. Locate the double filament bulb at the rear tail and stop service lamp. Locate the ground at the negative battery cable. 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 identifying components, 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 terminal of the same battery, following the wire to the negative terminal of the second battery. Follow the wire from the positive terminal of the second battery to the B terminal of the starter solenoid. Now continue on by following that same wire to the starter relay. From there take the red wire to the lower 30-amp circuit breaker. Next keep with the same red wire to the upper 30-amp circuit breaker. Going through that circuit breaker pick up the two-red/black wires and trace them to the harness/cable connector, pins 16 & 18 of the rear wiring harness. Continue through the connector to the front wiring harness 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 starter motor, 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 the neutral start switch. Go through the neutral start switch, leaving it on a VIO/BLK wire, going to the bottom left terminal of the starter relay. Now the starter relay is energized and the contacts closed. Leave the top left terminal of the starter relay and follow it to the S terminal of the starter solenoid. This will energize the starter solenoid closing its contacts. Now trace the wire leaving the M terminal over to the starter motor, go through the starter motor to the ground.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10B01PE 1 There is no solution for this practical exercise. The object of this PE is for the student to gain proficiency in reading and utilizing wiring schematics.
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PRACTICAL EXERCISE SHEET 62B10B01PE 2

Title
Identify the purpose of a battery, battery componen environmental procedures. 62B10B01 version ADT / Electrical Systems
Lesson Number / Title Introduction Motivator
Explain the importance of being able to properly un constructed, the operation of the battery, and how
NOTE: The instructor should inform the students of the requirements. (TLO Step 3)
At the completion of this lesson, you [the student] will: Action: Identify the purpose of a battery, bat
safety, and environmental procedure

Safety Requirements
Risk of skin and eye injury exists during battery tes along with connecting and disconnecting test equip are given extensive instruction on how to properly warned of the dangers present. Each student is p Risk of hearing damage exists during engine opera and required to wear aural protectors. Emergency will be available and their proper use demonstrated and instructors is mandatory during this practical e concerning PPE can be found in OSHA regulations CFR 1910.132-.133; 29 CFR 1910.132 and 138; a
Risk Assessment
There is the potential for battery acid spillage durin procedures. The possibility exists for spillage of fu engine operations. Adequate ventilation is require when battery load testing and charging procedures guidance can be found in OSHA regulations gover 1910.1200. Practical Exercise. State the complete, safety, risk assessment level, considerations.
* FM 11-60 * * * * * 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
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* * * * * * * * * * * * * * * * * *
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 9-8000 TM 11-6625-3199-14 FOS 20 ITRO-B TSP Wiring schematics
29 CFR 1910.1200 29 CFR 1910.132 29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95
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
Before presenting this lesson, Divide class in to tw
3. After 1 hour the groups will switch for an a
4. Ensure all materials are on hand and in qu
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1. Ensure that students have a study rubber gloves and safety goggles) battery charger and batteries. 2. Explain to students:
(a) The location of emergency showers a they are used. (b) Students will work in groups of two.
(c) Twenty-five minutes will be allotted fo Exercise.
(d) Following Problem #1, five minutes w solution with the instructor.
(e) Ten minutes will be allotted for Proble
(f) Following Problem #2, five minutes w review the solution.
(g) Ten minutes will be allotted for Proble
(h) Following Problem #3, five minutes w review the solution. 3. During entire testing procedure that they 4. Assist students as required.
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Procedures
Problem #1
Perform a specific gravity test on a battery IAW TM 9-6140-200-14. Annotate the results on the practical exercise work sheet in your study guide. When all students have completed this task the instructor will go over 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 the appropriate technical manuals. Annotate the results on the practical exercise work sheet in your study guide. When all students have completed this task the instructor will go over the results with the entire group. Readings: Before During After
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Problem #3
Properly recharge a battery IAW the instructors guidance, manufactures instructions and the appropriate technical manuals.
NOTE: Since battery chargers are not all alike, ensure you follow the instructors guidance when connecting the charger 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 the manufacturers manual.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10B01PE 2 There is no solution for this practical exercise. The object of this PE is for the student to gain proficiency in using battery testing and charging equipment.
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Identify TMDE used for electrical system testing. 62B10B01 version ADT / Electrical Systems
Explain the importance of being able to properly id system testing.
At the completion of this lesson, you [the student] will: Action: Identify TMDE used for electrical sys Safety Requirements
Risk of eye injury exists during power-up / power-d Is required to wear eye protection when connecting SPORT power cable at the battery. Risk of hearing operation. Each student is required to wear hearin operation. Risk of eye injury exists during battery c procedures. Each student Is required to wear eye disconnecting the circuit board to the battery. Risk throughout the exercise. Emergency showers and available and their proper use demonstrated. The instructors is mandatory during this practical exerc concerning PPE can be found in OSHA regulations CFR 1910.132-.133; 29 CFR 1910.132 and 138; a
Risk Assessment
Instructors should complete a risk assessment bef operations, or logistical activities. Risk assessmen identifying potential environmental hazards, develo decisions, implement controls, and insure proper s Performance Evaluation Practical Exercise.
State the complete safety, risk assessment level, a considerations.

* FM 11-60 * * * * * * * 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
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* * * * * * * * * *
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 9-8000 TM 11-6625-3199-14 FOS 20 ITRO-B TSP Wiring schematics
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
1. Before presenting this lesson, divide the class
2. Group #1 will do a PE on the SPORT or MSD. 3. Group #2 will do a PE on the Multimeter.
4. After 2 hours 15 minutes the groups will switch minutes.
5. Ensure all materials are on hand and in quanti
Procedures
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Group one: 1. Ensure that students have a study guide safety goggles and appropriate TM. 2. Assign students to a charging cart with a complete SPORT or MSD. 3. Explain to students: a) Students will work in groups of two. b) Instruction will be lock step, allowing all students to have the opportunity to understand the entire exercise. c) During battery connect and disconnect procedures safety goggles will be worn. d) During equipment operation hearing protection will be worn. 4. Assist students as required.
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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: NOTE: Actual equipment may be utilized instead of circuit boards. 1. Ensure that students have a study guide, multimeter and a circuit board. 2. Explain to students: a) They will work individually. b) They must utilize the multimeter set up for continuity to check all components mounted on the circuit boards to include conductors. c) Properly connect all conductors so the turn signals and high/low beam lights will function. d) Take completed circuit board to instructors table for operational test. e) That they must answer questions pertaining to automotive electricity prior to their circuit board being tested.
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Group two: Utilize a multimeter along with the knowledge you have gained in the previous electrical classes to perform the following tasks: 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.
Feedback Requirements
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10B01PE 3 There is no solution to this practical exercise. The object of this PE is for the student to gain proficiency in using TMDE.
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Troubleshoot a starting and charging system. 62B10B01 version ADT / Electrical Systems
Explain the importance of being able to properly tro charging system..
At the completion of this lesson, you [the student] will: Action: Troubleshoot a starting and charging Safety Requirements
1. Risk of eye injury exists during ba required to wear eye protection wh
2. Risk of hearing injury during equip required to wear hearing protectio
3. Risk of electrical shock exists thro
4. The use of PPE by students and in this practical exercise.
5. Further guidance concerning PPE regulations 29 CFR 1910.132-.138 CFR 1910.132 and 138; and 29 C
Emergency showers and eyewash stations will use demonstrated.
Risk Assessment
The possibility exists for spillage of fuel, oil, and a operations. Adequate ventilation is required during troubleshooting a starting and charging system pro Comply with Shop/Installation SOP/Operations ord hazardous materials. Performance Evaluation Practical Exercise. State the complete safety, risk assessment level, considerations.
* FM 11-60
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* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
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 9-8000 TM 11-6625-3199-14 FOS 20 ITRO-B TSP Wiring schematics 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
Student Materials:
NOTE: If specified equipment is not available f similar systems may be substituted. If available a request for wavier and supp submitted.
1. Before presenting this lesson, divi
2. Explain that they will do a round ro sites 3. Students will receive 3 hours and
4. Ensure all materials are on hand a
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Procedures
Site #1: Troubleshoot a starting system utilizing a digital multimeter: 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief students on safety requirements for site. 3. Explain to students: a) b) Students will work as a group and full participation from each student is required. Each student will demonstrate how to properly use the appropriate technical manual, electrical schematic and how to set up and perform tests with the multimeter. During battery connect and disconnect procedures safety goggles will be worn. During equipment operation hearing protection will be worn. Do not make any repairs with out approval of the instructor.
c) d) e)
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Site #1: Troubleshoot a starting system utilizing a digital multimeter 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief students on safety requirements for site. 3. Explain to students the following tasks will be performed: a) b) c) Reinforce locating components on MW24C wiring schematic Locate components on the MW24C Set multimeter up for the following measurements: (1) (2) (3) (4) d) e) f) g) Amperage DC Resistance Continuity Voltage DC
Utilize a digital multimeter to perform a battery voltage test troubleshoot Locate Starter Does Not Crank deficiency in the TM troubleshooting chart. Follow sequence outlined in the troubleshooting chart. Inform instructor of the fault when identified.
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Site #2 Troubleshoot a starting and charging system utilizing a MSD/ SPORT 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief student on safety requirements for site. 4. Explain to students: a) b) c) d) e) Students will work as a group and full participation from each student is required. Each student will demonstrate how to properly use the appropriate technical manual and how to set up and perform tests with the SPORT or MSD. During battery connect and disconnect procedures safety goggles will be worn. During equipment operation hearing protection will be worn. Do not make any repairs with out approval of the instructor.
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Site #2: Troubleshoot a starting and charging system utilizing a MSD / SPORT 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief student on safety requirements for site. 3. Explain to students they 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 GO chain. (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 NO GO 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 (PG 3-266 PARA 3-33)
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Site #3: Troubleshoot accessory circuits utilizing the digital multimeter: 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief student on safety requirements for site. 3. Explain to students: a) Students will work as a group and full participation from each student is required. b) Each student will demonstrate how to properly use the appropriate technical manual and how to set up and perform tests with the digital multimeter. c) During battery connect and disconnect procedures safety goggles will be worn. d) During equipment operation hearing protection will be worn. e) Do not make any repairs with out approval of the instructor. Assist students as required.
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Site #3: Troubleshoot accessory circuits utilizing the digital multimeter 1. Ensure that students have a study guide, PPE and appropriate TM. 2. Brief student on safety requirements for site. 3. Explain to students they will utilizing a digital multimeter to troubleshoot the following faults: a) On the MW24C Scoop Loader, utilize a digital multimeter to troubleshoot the following deficiency: Lights inoperative
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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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10B01PE 4 There is no solution for this practical exercise. The object of this PE is for the student to gain proficiency in using TMDE to troubleshoot a starting and charging system.
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Replace a switch, replace batteries, and repair a wiring harness. 62B10B01 version ADT / Electrical Systems
Explain the importance of being able to properly replace a switch, replace batteries, and repair a wiring harness.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 6) At the completion of this lesson, you [the student] will: Action: Repair a wiring harness, replace batteries and replace a switch.
Safety Requirements
Risk of skin and eye injury exist during battery disconnecting and connecting procedures. The possibility of electrical shock also exists. All personnel will wear eye protection. All jewelry of any kind (ID tags, watches, rings, etc) will be removed. All personnel will be provided and required to wear aural protectors while equipment is running. Emergency showers and eyewash stations will be available and their proper use demonstrated. The use of Personal protective Equipment (PPE) by students and instructors is mandatory. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low - Review the deliberate risk assessment, perform a daily risk assessment, ensure it is recorded on appropriate forms, signed by authorized command authority, and posted at the training site(s). Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation.
Achieve a GO on a performance evaluation in the time allotted.
Risk Assessment
Evaluation Instructional Lead-In Resource Requirements
State the complete safety, risk assessment level, and environmental considerations.
TM 5-3805-261-20 TM 5-3805-262-20 TSP 62B10B01

Student Materials:
TM 5-3805-261-20 TM 5-3805-262-20
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NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Before presenting this lesson, divide class into equal groups. Explain that they will do a round robin. Ensure all materials are on hand and in quantities needed. Ensure that students have a study guide, Personal Protective Equipment, and appropriate CD for the SPORT/MSD or TM reader. Brief students on safety requirements for site. Explain site requirements to students. Students will work as a group and full participation from each student is required. Student will demonstrate how to properly use the appropriate technical manual, SPOR/MSD or TM reader. Student will demonstrate their knowledge in inspecting, testing, and repairing a wiring harness and switch, and replacing a battery on a scoop loader. During battery connect and disconnect procedures PPE will be worn. During equipment operation hearing protection will be worn. Repairs will not be made without the approval of the instructor. Assist students as required.
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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 and correct 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 the instructor's guidance and troubleshooting procedures to determine the fault and correct it. Perform all actions without damage 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 TM provided, follow the instructor's guidance and troubleshooting procedures to determine the fault and correct it. Perform all actions without damage to the equipment or injury to personnel.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10B01PE 5 Station # 1: Students should have used the TM to locate the fault "Bucket does not return to digging position" and followed the procedures outlined to determine the Return to Dig Switch is faulty. Student should have followed the procedures outlined in the TM to replace the switch and verified the fault was corrected. Station # 2: Students should have used the TM to locate the fault "Engine does not crank" and followed the procedures outlined to determine the batteries are faulty. Student should have followed the procedures outlined in the TM and explained to the instructor the proper procedure to replace the batteries. NOTE: Instructor will insure the student understands the correct procedures to disconnect the batteries, remove the battery hold down bracket(s), remove the batteries, replace and reconnect them. Batteries will not be physically removed.
Station # 3: Students should have used the TM to locate the fault "All driving, tail and panel lights fail to operate" and followed the procedures outlined to determine a wire in the wiring harness is faulty. Students should have followed the instructor's guidance, repaired the faulty wire and verified the fault was corrected.
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DIESEL ENGINE SYSTEMS

PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10C01 version ADT PRACTICAL EXERCISE SHEET 62B10C01 PE1
Title Lesson Number / Title Introduction
Disassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems At this station, you have Caterpillar 3304 four-cycle diesel engines. You will use the supplied technical manual and your instructors guidance to disassemble the engines. In order to be a competent construction equipment repairer you must understand and be able to perform diesel engine repair and adjustments. During this practical exercise you will be introduced to some the techniques used to do this.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 2) At the completion of this lesson, you [the student] will: Action: Disassemble a diesel engine.
Motivator
Safety Requirements
Risk of hand and foot injury while handling heavy engine components and using special purpose tools and equipment. Foot and hand protection is required during these operations. Students are given extensive instructions on how to properly complete these operations and are warned of the dangers. Risk of hearing damage during engine operation. Hearing protection is required during engine operation. Risk of eye injury while working with POL products. Eye protection is required during these operations. The use of PPE by students and instructors is mandatory during this practical exercise. The use of Personal Protective Equipment (PPE) can be referenced in Occupational Safety and Health Administration (OSHA) regulation 29 CFR 1910.132-.138. Each student is briefed on the location and operation of the eye wash station. An instructor must be on site to supervise and to ensure safety equipment is used and procedures are adhered to during all operations. Low Potential environmental contamination through oil and fuel spilled during engine disassembly. Students are briefed on proper disposal of POL products and how to properly clean up spills. Ensure spill kits are available and there location identified. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Written examination and performance evaluation. NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson.
Risk Assessment Environmental Considerations
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Explain to students a. Safety is a top priority and will be monitored and enforced throughout this practical exercise. b. c. This PE is eleven hours long. You will be working in groups of four.
d. If you have any questions or problems during this PE contact an instructor prior to continuing.
Resource Requirements Instructor Materials:
OMRG25204 OMRG24828 OMRG25205 CTM86 CTM104 PC2527 PC2521 6SE201 PME201 SENR1189
Operation and Maintenance Manual Operation and Maintenance Manual Operation Manual Component Technical Manual Component Technical Manual Parts Catalog Parts Catalog Service Manual Parts Manual Disassembly and Reassembly Hazard Communication Personnel Protective Equipment General Requirements Eye and Face Protection Foot Protection Hand Protection Occupational Noise Exposure
May 96 Jan 96 May 96 Jul 99 Oct 98 Jun 99 Sep 99 Feb 84 Oct 77 Feb 98 Jul 96 01 Jul 2003 01 Jul 2003
SENR2569-03 Systems Test and Adjustment
29 CFR 1910.1200 29 CFR 1910.132
29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95 Eye Protection
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
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Student Materials:
Student Study Guide Equipment manuals extracts (1:4) Situation Sheets (1:4) Eye Protection Safety Boots Rubber Gloves Rubber Apron Coveralls
NOTE: Reinforce the safety procedures throughout this Practical Exercise. During the practical exercise ask the students questions pertaining to each system and individual components. This will verify they understand what makes up each system and what each component s function. If the students make an error in the procedures, stop and inform the students of the error before continuing. NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted.
a. Safety i. Ensure a safety briefing is conducted for each site as applicable. ii. Ensure safety is monitored and enforced throughout this practical exercise. b. Ensure each station has the applicable TMs and manufacturers references as required. c. Ensure all personal protective equipment (PPE) is available at the appropriate stations.
d. Ensure all required tools and TMDE are at each station. e. Divide class into groups of four. f. Ensure each station has a copy of the practical exercise sheet pertinent to that station.
g. Station requirements. The requirements for this station are: i. One technical manual (SENR1189, July 1996) ii. Situation Sheet #1 and Situation Sheet #2 iii.One torque wrench iv.Fuel for each engine v. One set of batteries vi.One general mechanics tool box
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h. Assist students as required.
Procedures
NOTE: These procedures are based on the use of a CAT 3304 engine. Each school should adjust the procedures to accommodate the engine being used. 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 remove wires. Reinstall nuts on alternator. c. Loosen mounting bolts and support bracket bolts. Move alternator towards engine to loosen 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 on shelf 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. Remove wire-mounting screw from solenoid. c. Remove positive and negative wires (large black leads) and solenoid wire from starter. Gather all loose wiring together and fold back onto engine stand behind slave cable 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-mounting bolts. NOTE: Starter weighs 65 pounds.
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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 engine turning tool.
3) Installation of Engine Turning Tool a. Mount engine turning tool in place of starter with flat side of gear shaft support bracket facing out using starter gasket and three (3) starter mounting bolts. Tighten starter bolts using 5/8 boxed-end wrench. b. Insert small end of geared shaft into hole in support bracket. Geared end must engage ring gear on flywheel. c. When complete, small-geared end of shaft should engage flywheel ring gear and shaft 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 accomplished to the instructor. NOTE: NOTE: NOTE: Ask students to determine which method they will use, Timing Pointer or Timing Bolt Hole? ANSWER: TIMING BOLT HOLE Ask students, "What is the normal direction of rotation for this engine?" The answer is counterclockwise when viewed from the flywheel end. Ask students, "Why must the engine be rotated clockwise?" The answer is to remove play from the timing gears. 2) Students will utilize the 1/2" ratchet for this procedure. Ratchet will be replaced in bottom of toolbox when procedure is completed. 3) To achieve 30 clockwise rotation, place ratchet in end of turning tool with handle of ratchet pointed down and touching the side of engine. Pull up on handle and rotate engine with ratchet until ratchet handle is all the way up and touching the side of engine. Ratchet will be turned seven (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 can marked FUEL INJECTION PUMP & GOVERNOR. 6) Insert 3/8" bolt in timing bolt hole and have students rotate engine counterclockwise while applying finger pressure to 3/8" bolt. When bolt slides into hole provided in flywheel, the No. 1 piston is at top center. 7) Students will check rocker arm assembly per instructions in manual to determine if engine is in Top Center Compression Position for No. 1 piston. Students will raise their hand when finished and wait for instructor.
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8) Instructor should check rocker arm assemblies of other pistons before checking the rocker arm assemblies of No. 1 piston. If timing is incorrect, ask students how they checked timing and which rocker arm assembly is for No. 1 piston. Explain procedure for checking timing and have students remove bolt from timing hole, slightly rotate engine counter-clockwise, reinsert bolt in timing hole, and continue to rotate engine until bolt slides into flywheel again. Instructor will check 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 air cleaner to turbocharger. b. Remove two (2) nuts and two (2) bolts holding air cleaner assembly to support bracket 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 work bench 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 intake manifold 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 the turbocharger. 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 exhaust manifold. b. Hold exhaust pipe to turbocharger coupling and remove exhaust pipe and coupling from turbocharger as a unit. (Coupling is cast metal and may crack or break if dropped). c. Place exhaust pipe and coupling assembly on workbench and pull coupling from exhaust pipe.
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d. Wrap coupling in rag and place in can marked TURBO. 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 impeller in 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 from engine. 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 trapped in 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 fit over 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 the turbocharger. Do not remove it from the turbocharger. Cover/tie off exposed openings on turbocharger and oil return tube. Place on shelf. Reinstall nuts/bolts and gasket (if removed) in exhaust manifold. Cover/tie off opening in exhaust manifold and place cap in oil return tube hole.
j. k.
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 bucket provided to drain system of water. Buckets will be dumped outside, away from building. b. Remove radiator support bracket, reinstall bolts/nuts on engine and bracket. Place bracket on shelf.
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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 on floor 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. e. Loosen two (2) lower water pump hose clamps and slide water pump lower hose off pump. 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 pump housing. i. j. k. Pull water pump away from engine and remove. Reinstall upper gasket (if removed) and four bolts in engine block. 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 between temperature 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: NOTE: All personnel must wear safety goggles/glasses during fuel procedures. THIS INCLUDES INSTRUCTORS. 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 with No. 1 injector line at the fuel injection pump housing. Loosen all nuts on the fuel pump from front to rear.
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b. Loosen the fuel injection line nuts at the fuel injection valves working from front to rear. Hold the top of each fuel injection valve with a 15/16 wrench and loosen fuel injection 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 place inverted assembly on workbench.
d. Install screw-in type protector caps on ends of fuel line nuts and place assembly carefully on shelf. e. Install push-on type protector caps on fuel injection valves and fuel pump. f. Place fuel injection line assembly underneath workbench. DO NOT place any other components 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 pump and remove. Loosen fuel line nut on fuel return line connected to the fuel injection pump. Cover/plug ends of supply and returns lines. Place fuel supply line underneath the workbench and ensure students do not set anything on top of it. Fold fuel return line down along side of engine stand. Do not let fuel return line hang or lay on 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 not loosen by hand students will inform instructor. After filter is loosened, unscrew it from the 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 will keep contaminants out of fuel. e. Place push on type plastic cap over threads of fuel filter mounting base.
NOTE:
Insure students 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 Injection Pump and Governor Assembly. Students in each group should work individually or in pairs to accomplish these tasks. a. Remove two (2) bolts securing exhaust manifold heat shield to mounting brackets. Place heat shield underneath workbench.
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b. Loosen nut on end of tube between air inlet elbow and air/fuel ratio control. Remove line and cap/plug both ends. Cap fitting on air/fuel ration control. Place line under workbench. 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 and fuel 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 on workbench. 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. 4) Removal of Fuel Injection Pump and Governor Assembly
NOTE: NOTE:
Fuel Injection Pump weighs approximately 53 lbs. 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 a 9/16 boxed-end wrench to remove the BOTTOM two (2) nuts and washers. One student will support fuel pump while the TOP nut and washer is removed using the following tool combination IN ORDER: 9/16 socket, 5" and 10" extension, universal joint and speeder bar. Two (2) students will carry the fuel injection pump to the workbench.
NOTE:
Instructor will monitor students as fuel pump and governor assembly is removed from studs and placed on workbench. b. Fuel injection pump will be positioned on workbench the back of pump rests on short wooden block provided. Position pump on workbench, leaving room for cylinder head placement. 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. If any O-ring is missing, look for it on and around engine or on the ground. If it cannot be found, replace.
NOTE:
Ensure students use dry sweep to clean up any fuel spilled at this point.
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d. Cover entire fuel pump with large rag. Reinstall timing gear cover on engine and hand tighten nuts. Cover/tie off opening where the fuel injection pump was removed from. 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 cylinders and 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 with others. NOTE: Exhaust manifold is heavy and fragile. c. Using a two-person carry, carefully remove exhaust manifold from engine and place on 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 in EXH MAN can. e. Place rag in each hole of cylinder head created by removal of exhaust manifold. Do not let rags hang down below cylinder head. G. REMOVAL OF ROCKER ARM ASSEMBLY AND PUSH RODS 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 tuck one rag into hole around each set of push rods. NOTE: Locknuts and adjustment screws have sharp burrs. Use care when loosening locknuts to avoid cuts and scrapes on hands. c. Loosen valve adjustment locknut, back out adjustment screw two (2) turns, and snug down locknut. Repeat for all valves. Do not over tighten locknuts. This will prevent a bent 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 to guard 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 but do not remove bolts from assembly.
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e. Place one hand under each end of the rocker arm shaft, lift up slightly, shake assembly to ensure push rods do not stick to rocker arms, and then lift assembly out of cylinder head. Place assembly, with threaded ends of bolts pointed down, in valve cover. 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 and placed 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 W pattern moving alternately left and right away from center until all are loose. Utilize speeder wrench to free all bolts from threads. As bolts and washers are removed place them, head end first, in can marked HEAD BOLTS. Ensure washers remain on bolts. b. Loosen the seven (7) air intake manifold head bolts using speeder wrench and 9/16 socket. Start at center and work left to right until all are loose. Place, head end first, in can marked HEAD BOLTS. c. Remove air cleaner support bracket and place on shelf. Reinstall bolts and washers on cylinder head.
d. Screw two (2) eye bolts into threaded holes provided on opposite ends of cylinder head. 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 cylinder head. 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 is centered over cylinder head.
g. One student will stand on each side of cylinder head with hands on TOP of cylinder head and guide it as it is lifted. Instructor will operate hoist.
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NOTE:
Cylinder head weighs 142 lbs. Warn students not to place fingers or hands under cylinder head at any time for any reason. h. Raise cylinder head approximately 8" and wheel away from block. Students will guide head to prevent it from swinging. i. j. Wheel cylinder head to work bench and position it over two (2) wooden blocks placed at each end of head. Students will guide cylinder head as it is slowly lowered onto wooden blocks. Ensure blocks are positioned so they don't rest on valves. Caution students once again to keep hands and fingers from under cylinder head. Disconnect hoist and lifting shackle. Remove eyebolts and cover head with rags. Remove head gasket from engine block at cylinder side being careful not to damage gasket. Wipe down and place behind cylinder head.
k.
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 marked TAGS. Remove rags from holes in spacer plate. c. Students will take hold of each end of spacer plate and lift it straight up from the block. Wipe down spacer plate and place behind cylinder head.
d. Carefully remove spacer plate gasket from engine. Wipe down gasket and place gasket behind cylinder head. e. Wipe down top of block. Cover top of block, spacer plate, and gaskets with rags. Police up area around engine.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10C01 PE1 There are no set solutions for this practical exercise. These engines do not have induced faults. The sole purpose of this period of instruction is to provide the students with the experience of using the references and to familiarize them with various engine subsystems.
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PRACTICAL EXERCISE SHEET 62B10C01 PE2

Reassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems At this station, you have Caterpillar 3304 four-cycle diesel engines. You will use the supplied technical manual and your instructors guidance to reassemble the engines. In order to be a competent construction equipment repairer you must understand and be able to perform diesel engine repair and adjustments. During this practical exercise you will be introduced to some the techniques used to do this.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 3) At the completion of this lesson, you [the student] will: Action: Reassemble a diesel engine.
Motivator
Safety Requirements
WARNING: Although there are no induced faults in the engines it is possible for one of the systems on the engines to fail through mistakes made by the students during reassembly. Risk of hand and foot injury while handling heavy engine components and using special purpose tools and equipment. Foot and hand protection is required during these operations. Students are given extensive instructions on how to properly complete these operations and are warned of the dangers. Risk of hearing damage during engine operation. Hearing protection is required during engine operation. Risk of eye injury while working with POL products. Eye protection is required during these operations. The use of PPE by students and instructors is mandatory during this practical exercise. The use of Personal Protective Equipment (PPE) can be referenced in Occupational Safety and Health Administration (OSHA) regulation 29 CFR 1910.132-.138. Each student is briefed on the location and operation of the eye wash station. An instructor must be on site to supervise and to ensure safety equipment is used and procedures are adhered to during all operations.
Low Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Inform the students that the critical tasks of replacing the fuel line, fuel filter, fuel pump, injector pump, hand primer pump, air filter, turbocharger, oil line, water pump, thermostat, drive belts, engine cooling fan, radiator and coolant hose will be evaluated during this practical exercise. NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson.
Evaluation
Instructional Lead-In
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Lead-In
Explain to students a. Safety is a top priority and will be monitored and enforced throughout this practical exercise. b. c. This PE is eighteen hours long. You will be working in groups of four.
d. If you have any questions or problems during this PE contact an instructor prior to continuing.
29 CFR 1910.1200 29 CFR 1910.132
29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95 Eye Protection Hearing Protection
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
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Student Materials:
Student Study Guide Equipment manuals extracts (1:4) Situation sheets (1:4) Eye Protection Safety Boots Rubber Gloves Rubber Apron Coveralls
NOTE: Reinforce the safety procedures throughout this Practical Exercise. During the practical exercise ask the students questions pertaining to each system and individual components. This will verify they understand what makes up each system and what each component s function. If the students make an error in the procedures, stop and inform the students of the error before continuing. NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Instructors guidance a. Safety i. Ensure a safety briefing is conducted for each site as applicable. ii. Ensure safety is monitored and enforced throughout this practical exercise. b. Ensure each station has the applicable TMs and manufacturers references as required. c. Ensure all personal protective equipment (PPE) is available at the appropriate stations.
d. Ensure all required tools and TMDE are at each station. e. Divide class into groups of four. f. Ensure each station has a copy of the practical exercise sheet pertinent to that station.
g. Station requirements. The requirements for this station are: i. One technical manual (SENR1189, July 1996) ii. Situation Sheet #1 and Situation Sheet #2
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iii.One torque wrench iv.One can of fuel for each engine v. One set of batteries h. Assist students as required.
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Procedures
NOTE: These procedures are based on the use of a CAT 3304 engine. Each school should adjust the procedures to accommodate the engine being used. 1. REASSEMBLY OF ENGINE NOTE: Instructor will guide student through Practical Exercise. 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 clean rags. 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 on cylinder 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 straight down on the cylinder block.
d. Install yellow o-ring on oil tube on top of spacer plate. Install water seals in appropriate holes on spacer plate. Ensure smaller water seals ARE NOT placed in cylinder 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 aligned with holes on spacer plate. b. Remove ALL rags from cylinder head and place them on the workbench. They will be used 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 the workbench. 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 to ensure 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 to equipment.
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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 is lowered onto the engine block. f. Slowly lower the cylinder head onto the engine block. Ensure students know to guide the dowels at each end of the engine block into the appropriate holes on the bottom of 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. Install 5 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 in cylinder 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 to the rear. b. Remove rag from hole the push rod will go in. Remove push rod from wooden block and wipe it down with a rag c. NOTE: Using a flashlight, guide the end of the push rod on to the TOP of the lifter it originally came off of.
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 to prevent 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 rocker arm 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. Once bolts are aligned with bolt holes, lower rocker arm assembly, making sure the rocker arms engage the valves and the push rods.
d. Once rocker arm assembly is in place and the rocker arms are engaged with the push rods, 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). Instruct students to become familiar with torque sequence. NOTE: NOTE: NOTE: If head bolts are NOT torqued in sequence, possible engine damage could occur. Instructor will show students the proper use of the torque wrench. Instructor will check the torque on each bolt after each tightening sequence. If any bolt in the sequence is 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 the cylinder head.
C. INSTALLATION OF EXHAUST SYSTEM COMPONENTS 1) Install Exhaust Manifold a. Remove all rags from exhaust ports on cylinder head and exhaust manifold.
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b. Clean all gasket surfaces around exhaust ports on cylinder head and exhaust manifold. c. NOTE: Put new gaskets in position on studs, ensuring that the words THIS END OUT is facing outward and is right-side up
Instructor will tell students to 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 and last 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 with the holes for bolts on top. Install the remainder of the washers and nuts. f. Torque ALL manifold nuts to 25 lb ft.
D. INSTALLATION OF FUEL SYSTEM COMPONENTS NOTE: NOTE: All personnel must wear safety goggles/glasses during fuel procedures. THIS INCLUDES INSTRUCTORS. 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 the gasket. b. Install timing pin in to hole where cover was located. Timing pin will rest on fuel injection pump camshaft. c. Install the bolt that holds the fuel injection pump drive gear into the fuel injection pump camshaft without the washer. This will allow the camshaft in the fuel system to be turned.
d. Put pressure on the end of the timing pin and turn the camshaft slowly until the timing pin drops into the groove (slot) in the camshaft. The fuel injection pump is now set to inject fuel into the No. 1 cylinder. NOTE: Instructor will ensure timing pin is NOT removed e. Leave the timing pin in position in the groove (slot). Remove the bolt from the end of the camshaft. Place bolt back in FUEL INJ PUMP can.
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2) Install the Fuel Injection Pump and Governor Assembly NOTE: Instructor will 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 injection pump drive gear.
d. Install the three (3) nuts on studs to hold the fuel injection pump to the engine. Install the two (2) bolts that screw into the bottom of the fuel injection pump. Tighten all nuts 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: Instructor will verify the bolt was torqued properly. 1) The following components/accessories must be installed after installing the Fuel Injection Pump and Governor Assembly. Students in each group should work individually or in pairs to accomplish these tasks. a. Mount exhaust manifold heat shield and install two (2) bolts to secure exhaust manifold heat shield to mounting brackets. b. Install tube between air inlet elbow and air/fuel ratio control. Only the end of the line connecting to the air/fuel ration control can be mounted. Tighten the fitting until line cannot be wiggled inside fitting. DO NOT OVER-TIGHTEN. c. Connect two (2) wires to fuel shut-off solenoid. DO NOT OVERTIGHTEN screws. Remove tags marking wires (if any).
d. Inspect the timing gear cover gasket and install timing gear cover. Tighten nuts in a star 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 seal with 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 gasket makes contact with the base, tighten the filter an additional 1/2 turn.
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c.
Install and tighten fuel inlet (between the primary filter and fuel transfer pump) and return 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 until they are finger tight. c. Students will utilize 3/4" line wrench to tighten all fuel injection line nuts beginning with No. 1 injector line at the fuel injection pump housing. Tighten all nuts on the fuel injection pump from front to rear.
d. Tighten the fuel injection line nuts at the fuel injection valves working from front to rear. Hold the top of each fuel injection valve with a 15/16 wrench and tighten fuel injection 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. Clearance will be checked with 0.017. 0.015 blade will drag slightly between the rocker arm and 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 1 and 3. 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 the valve. 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. 4 piston 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. Clearance will be checked with
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0.017. 0.015 blade will drag slightly between the rocker arm and 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 and 4. 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 the valve. 0.027 blade will not pass through.
d. After valve adjustments are correct, ensure the nuts for the valve adjustment screws are 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. NOTE: Install new gasket, install regulator housing and 4 each mounting bolts
Make sure the vent hole is open. The cylinder head can be damaged if the vent hole is not open or the gasket 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.
d. Install water pump to water pump housing. Rotate bottom of water pump inward towards engine and seat pump into housing. e. Install two (2) bolts into water pump housing. Install two (2) bolts into upper elbow housing. 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.
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i. j. NOTE:
Connect water temp. sending unit to water pump. Fill cooling system with proper coolant to the correct level.
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 manifold and turbocharger is positioned properly. Ensure the oil drain line is inserted prior to placing the turbocharger directly on the manifold. Do not to pinch the O-ring on the drain 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 in positioned 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 in exhaust pipe. (Coupling is cast metal and may crack or break if dropped). c. Position exhaust pipe/coupling assembly next to turbocharger on engine. Insert small end 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. b. Rotate inlet elbow so other end of elbow is in position on the cylinder head. Ensure gasket is in place and positioned properly. c. Install and tighten four (4) bolts to secure inlet elbow to cylinder head. Tighten hose clamps on hose connecting inlet elbow to turbocharger.
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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 position air filter housing on engine. b. Install two (2) nuts and two (2) bolts holding air cleaner assembly to support bracket at 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 will support the rear of the starter while another installs and tightens three (3) starter mounting 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 the fuel 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 pressure gauge reads completely in the green zone. NOTE: When the fuel injection lines are loosened or tightened on the fuel injection valves, two wrenches must be used. The fuel injection valve must be held in place with a wrench or damage to the fuel injection nozzle will result.
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3) Loosen the fuel line nuts at the fuel injection valves, one at a time, from front to rear, until fuel without air comes from the fuel injection line nut. Tighten the fuel injection line nut after the air is 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. Let engine cool before removing fill cap from radiator. Loosen the filler cap to the first stop and let the pressure out of the cooling system, then remove the filler cap. Hot coolant and steam can cause personal 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. Tighten or replace all lines and hoses that leak. 3) Lubricate System: Check for proper operation and condition of the lubrication system. There should be no leaks. Inspect all oil lines and hoses for cracks,
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frays and wear that could cause leaks. Tighten or replace all lines and hoses that leak. 4) Intake System: Check for the proper operation and condition of the intake system. Ensure that the 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. Look for 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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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10C01 PE2 There are no set solutions for this practical exercise. These engines do not have induced faults. The sole purpose of this period of instruction is to provide the students with the experience of using the references and to familiarize them with various engine subsystems.
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PRACTICAL EXERCISE SHEET 62B10C01 PE3

Title
Implement diagnostic test and adjustment procedures on diesel engines and components. 62B10C01 version ADT / Diesel Engine Systems
Lesson Number / Title Introduction Motivator
In order to be a competent construction equipment repairer you must understand and be able to perform diesel engine troubleshooting and adjustments. During this practical exercise you will be introduced to some the techniques used to do this.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 5) At the completion of this lesson, you [the student] will: Action: Implement diagnostic test and adjustment procedures on diesel
engines and components.

Safety Requirements
There is a risk of injury while correcting air, cooling, fuel, and lubrication malfunctions. Students will be given extensive instruction on how to properly complete these operations and will be warned of the dangers. All personnel will wear eye protection and an instructor will show students the location and operation of the eye wash station. All personnel will wear hearing protection while the engines are in operation. All jewelry will be removed prior to beginning any practical exercises. Instructors must be on site to supervise, ensure procedures are adhered to during all operations and ensure safety equipment and PPE are on hand and used properly. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95.
Low Potential environmental contamination through oil and fuel spilled during engine diagnostic test and adjustment procedures on diesel engines and components. . Students will be briefed on proper disposal of POL products and how to properly clean up spills. Ensure spill kits are available and there location identified. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Written examination and performance evaluation. NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson. Explain to students
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A. Safety is a top priority and will be monitored and enforced throughout this practical exercise. B. This PE is 17 hours long and consists of 6 stations. 1) Each station will be 3.5 hours long, followed by a seven to ten minute review. 2) You will work in groups of four. 3) If you have any questions or problems during this PE, contact an instructor prior to continuing. C. At all stations, you will correct the problems assigned to you by the instructor.
29 CFR 1910.1200 29 CFR 1910.132
29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95 Eye Protection Hearing Protection
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
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Student Materials:
Student Study Guide Equipment manuals extracts Practical exercise sheets Eye Protection Hearing Protection Coveralls
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. A. Safety requirements 1) Ensure a safety briefing is conducted for each site as applicable. 2) Ensure safety is monitored and enforced throughout this practical exercise. B. Ensure each station has the applicable TMs and manufacturers references as required. C. Ensure all personal protective equipment (PPE) is available at the appropriate stations. D. Ensure all required tools and TMDE are at each station. E. Divide class into groups of four. F. Ensure each station has a copy of the practical exercise sheet pertinent to that station. G. Station requirements 1) Ensure Station #1 has a MSD or SPORT-ICE and an air induction system fault. Ensure each student has a copy of the practical exercise sheet. 2) Ensure Station #2 has a MSD or SPORT-ICE and a fuel system fault. Ensure each student has a copy of the practical exercise sheet. 3) Ensure Station #3 has a MSD or SPORT-ICE and a lubrication system fault. Ensure each student has a copy of the practical exercise sheet. 4) Ensure Station #4 has a radiator test kit and a cooling system fault. Ensure each student Instructions has a copy of the practical exercise sheet.
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5) Ensure Station #5 has a 3/4 line wrench and sufficient rags on-hand. Ensure each student has a copy of the practical exercise sheet. 6) Ensure Station #6 has a cylinder compression tester and a 1 wrench. Ensure each student has a copy of the practical exercise sheet. H. Assist students as required.
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Procedures
Station #1 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 air induction system. Perform all steps and tests to verify the air induction system 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.
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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 fuel system 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.
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Station #3 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 lubrication system. Perform all steps and tests to verify the lubrication system 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.
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Station #4 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 cooling system. Perform all steps and tests to verify the cooling system 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.
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Station #5 At this station, you have a four-stroke diesel engine, TMDE, and the applicable TMs and references. Your supervisor informs you that the engine runs rough. Using the applicable TMs and references, check the engine to correct the malfunction. Perform all the steps and tests to verify that the engine is operational. After checking the system, if you do not find any faults, report your findings to the instructor.
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Station #6 At this station, you have a four-stroke diesel engine, TMDE, and the applicable TMs and references. Your supervisor informs you that the engine lacks power. Using the applicable TMs and references, check the engine to correct the malfunction. Perform all the steps and tests to verify that the engine is operational. After checking the engine, if you do not find any faults, report your findings to the instructor.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10C01 PE3 Station #1 The student, using the TM, should conduct an air inlet restriction test or air box pressure test and should get one of the following results: 1. Air Inlet Restriction Caterpillar 3306: Caterpillar 3304: Detroit 3-53N: Detroit 4-53N: 30 inches of water or less 30 inches of water or less 12 inches of water or less 12 inches of water or less
If test results are other than specified repair or replace as necessary. a. b. 2. Replace the air filter Replace the turbocharger Air Box Pressure (Detroit 3-53N / 4-53N): At Max. Exhaust Back Pressure: 5.4 inches of mercury At Zero Exhaust Back Pressure: 3.7 inches of mercury
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Station #2 The student using the TM, should conduct a fuel pressure test or an air in the fuel test and should get on of the following results: 1. Fuel Pressure Test: Caterpillar 3304 / 3306: not less than 15 psi John Deere 4.5L / 6.8L: not less than 14 psi Detroit 3-53N / 4-53N: 45-70 psi (min. 35 psi) 2. Air in the Fuel Test (John Deere 4.5L / 6.8L) There should be no bubbles present If the test results indicate a problem, check the suction side of the fuel system. Follow the troubleshooting steps and replace or repair as necessary. 1. 2. 3. 4. Fuel tank Hand primer pump(s). Primary fuel filter Hoses and fittings connecting the listed components
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Station #3 The student using the TM, should conduct an oil pressure test and check the operation of the oil pressure gauge. Student should get one of the following results: Oil Pressure Test: Caterpillar 3304 / 3306: not less than 20 psi John Deere 4.5L / 6.8L: not less than 14 psi Detroit 3-53N / 4-53N: not less than 30 psi If test results are not as specified repair or replace parts as necessary. 1. 2. Oil line connected to oil pressure gauge. Oil pressure gauge.
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Station #4 The student, using the TM, should follow the appropriate troubleshooting steps to find the problem. Student should get one of the following results: Cooling system troubleshooting results: 1. Cooling fan inoperable and needs to be replaced. 2. Radiator hose leaks and needs to be replaced. 3. Vee belts worn out and need to be replaced. 4. Temperature regulator not functioning and needs to be replaced. 5. Water pump leaks and needs to be replaced. 6. Radiator has a leak in the core and needs to be replaced.
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Station #5 The student, using the TM, should recognize that there is one misfiring cylinder. Student should follow the trouble shooting steps to repair or replace as necessary the following items. 1. Replace fuel line. 2. Replace injection pump.
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Station #6 There are no set solutions for this practical exercise. These engines do not have an induced fault. The sole purpose of this period of instruction is to provide students with the experience using the TM and references to logically troubleshoot the engine and use the TMDE to verify their findings.
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HYDRAULIC SYSTEMS
PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10D01 version ADT PRACTICAL EXERCISE SHEET 62B10D01PE1
Repair and replace a hydraulic cylinder. 62B10D01 version ADT / Hydraulic Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. During this lesson you will learn how to repair and replace hydraulic cylinders. It will become clear that replacing hydraulic cylinders and repairing hydraulic cylinders is not complicated and this, in turn, will make you a more competent mechanic because this is one of the main components that fail in a hydraulic system.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 2) At the completion of this lesson, you [the student] will: Action: Repair and replace a hydraulic cylinder.
Motivator
Safety Requirements
Risk of burns, skin and eye injury exists while working with hand tools and pressurized fluids. Students will wear Personal Protective Equipment (PPE), and relieve hydraulic pressure when working with hydraulic systems at all times. Risk of hand and foot injury exists while moving hydraulic cylinders, use two person carry when moving cylinders. Risk of injury and damage to equipment exists while students operate equipment. Ensure personnel are clear and TMDE is setup IAW the applicable TM prior to starting equipment. Use three points of contact when mounting or dismounting equipment. Remove all jewelry to include ID tags and wedding bands when working on equipment. In case of eye contact with hydraulic fluids, eyewash will be used immediately. Use caution around moving parts. Students will be provided and required to wear PPE while equipment is running. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low Petroleum oil and lubricants (POL) can be hazardous to the environment if not disposed of properly. The possibility exists for the spillage of fuel, oil, and antifreeze during equipment operations. Ensure spill kits are available and there location identified. Adequate ventilation is required during equipment operations in the maintenance shop. Comply with Shop/Installation SOP/Operations order requirements for disposal of hazardous materials. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Inform students the critical task repair a hydraulic cylinder will be evaluated during this practical exercise.
Evaluation
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this practical exercise.

Instructional Lead-In Resource Requirements
Inform students of the Learning Step/Activity requirements. State the action, safety, and environmental considerations.
TM 5-2350-262-34 TM 5-3805-262-20 D01 TSP Eye Protection

Student Materials:
Eye Protection Safety Boots Coveralls TM 5-2350-262-34 TM 5-3805-262-20

NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Inform students of the Learning Step/Activity requirements. State the complete action, safety, and environmental considerations. 1. Explain to students: They will conduct a practical exercise on replacing a hydraulic cylinder and line and repairing a hydraulic cylinder. a. The class will be broken down in two groups. b. Each group will have two hours to complete the practical exercise. c. Following the PE, ten minutes will be allotted to review the PE with the instructor. d. Stations will be conducted in round robin style e. Ensure each site has tools, TMs, and is setup and available. 2. PE. a. Introduction. b. Motivation statement.
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c.
State Action.
d. Problem #1 requirements: 1) Ensure each student has a general mechanic tool kit, three pound hammer, strap and oil can available. 2) Students will select the proper cylinder to be removed. 3) Students will follow all safety procedures.
Procedures
Problem One: Replace a hydraulic cylinder. At this station you are in an Organizational Maintenance environment. You have a MW24C Scoop Loader. Your supervisor has told you to replace the bucket clamshell cylinders. Using applicable TMs and tools remove and replace the bucket clamshell cylinders. Follow all safety procedures and insure you are wearing eye protection, coveralls and safety boots.
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Hydraulic Cylinder Removal NOTE: Plug or cap lines disconnected or removed and plug clam cylinder assembly ports in the following steps to 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. 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 another mechanic. You have been instructed by your supervisor to repair the cylinder and bring the equipment back to operational status. Follow all safety procedures and insure you are wearing eye protection, coveralls and safety boots.
Cylinder Disassembly 1. 2. 3. Remove two plugs from oil ports. Remove set screw from cylinder housing. Unscrew cylinder head by turning counterclockwise using spanner wrench.
NOTE: Use two personnel when removing piston rod from housing. 4. 5. 6. 7. 8. Remove piston rod from cylinder housing and place on the bench. Remove cylinder housing from vise and place it on the floor in front of the bench. Place the yoke of the piston rod in the vice, with the piston facing inward. Remove piston locknut using 3\4 drive socket. 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. 2. Remove two wear rings from the piston. Remove the packing and the retainer from the cylinder head.
Cylinder Assembly 1. 2. 3. 4. 5. 6. 7. Replace all seals Install cylinder head on piston rod with wiper seal facing yoke. (Use care not to mar or scratch rod during installation) Install piston onto the piston rod with open end of piston facing the piston rod threads. Install piston locknut on piston rod and tighten nut with 3\4 drive socket. Remove piston rod from the vise. Place cylinder in the vice and install piston rod. Using spanner wrench install cylinder head into the cylinder.(ensure chalk marks are lined up
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.
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9.
Install two caps into oil ports.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10D01PE1 Problem #1: Replace a Hydraulic cylinder. Students should have followed all safety procedures and worn eye protection, coveralls and safety boots. Replaced the hydraulic cylinder IAW the applicable reference to restore proper operation of the clamshell using the steps below: Hydraulic Cylinder Removal NOTE: Students should have plugged or capped lines disconnected or removed and plugged clam cylinder assembly ports in the following steps to prevent foreign matter from entering the hydraulic system. The students should have: 1. Tagged and disconnected lines from cylinder assembly ports. 2. At top of cylinder assembly, removed locknut and cap screw. 3. Used a hammer and a brass drift to drive pin from cylinder rod eye. 4. At the bottom of cylinder assembly, loosened and removed lock nut and cap-screw 5. Used hammer and a brass drift to drive pin out of cylinder tube yoke. 6. Removed clam cylinder assembly from bucket. Installation 1. Positioned clam cylinder assembly on rear of bucket. 2. Aligned cylinder tube yoke hole at bottom of cylinder with pivot hole in bucket. 3. Started pin into pivot hole at bottom of cylinder and insured hole in pin was aligned with hole in cylinder. 4. Removed plugs and reconnect lines to cylinder assembly ports. 5. Used hammer and a brass drift to drive pin into place at the bottom of the cylinder. 6. Installed and tightened cap screw and lock nut at the bottom of the cylinder.
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Problem #2: Repair a hydraulic cylinder Students should have followed all safety procedures and worn eye protection, coveralls and safety boots. Repaired the hydraulic cylinder IAW the applicable reference following the steps below: 1. Removed two plugs from oil ports.
NOTE: Ask students what type cylinder they are working on. 2. Removed setscrew from cylinder housing.
NOTE: Tell students you would normally mark position of setscrew hole using chalk. 3. Unscrewed cylinder head by turning counterclockwise using a spanner wrench.
NOTE: Student should have used two personnel when removing piston rod from housing. 4. 5. 6. 7. 8. Removed piston rod from cylinder housing and placed on the bench. Removed cylinder housing from vise and placed it on the floor in front of the bench. Placed the yoke of the piston rod in the vice, with the piston facing inward. Removed piston locknut using 3\4 drive socket. Removed piston from piston rod.
NOTE: Student should have used caution when removing cylinder head. Threads are sharp and will cut them. 9. Removed cylinder head from the piston rod (lubricated piston rod if needed).
Seal removal NOTE: Question students: Seals are used in two main applications. What are they? 1. Removed two wear rings from the piston.
NOTE: Question students: Which of the two applications do these seals fall under? 2. Removed the packing and the retainer from the cylinder head.
NOTE: Question students: Which of the two main applications are these seals? NOTE: If time permits instructor will continue removing and discussing various types of seals. Cylinder Assembly 1. 2. 3. 4. 5. Replaced all seals. Installed cylinder head on piston rod with wiper seal facing yoke. (Used care not to mar or scratch rod during installation) Installed piston onto the piston rod with open end of piston facing the piston rod threads. Installed piston locknut on piston rod and tighten nut with 3\4 drive socket. Removed piston rod from the vise.
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6. 7.
Placed cylinder in the vice and installed piston rod. Used spanner wrench to install cylinder head into the cylinder (ensured chalk marks are lined up).
NOTE: Inform the students that normally the setscrew would be replaced with a new one but for training purpose the same one is being used. 8. 9. Secured cylinder head into cylinder with setscrew. Installed two caps into oil ports.
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PRACTICAL EXERCISE SHEET 62B10D01PE2

Interpret hydraulic schematics.
62B10D01 version ADT / Hydraulic Syste
Introduce the instructors for this practical subject being covered.
Motivator
It will become clear that Interpreting hydr learning how to properly troubleshoot and
NOTE: The instructor should inform the stude requirements. (TLO Step 3)
At the completion of this lesson, you [the stud Action: Interpret hydraulic schem Safety Requirements
Risk of burns, skin and eye injury exists w Students will wear Personal Protective Eq pressure when working with hydraulic sys damage to equipment exists while studen are clear and TMDE is setup IAW the ap three points of contact when mounting or jewelry to include ID tags and wedding ba of eye contact with hydraulic fluids, eyew around moving parts. Students will be pr equipment is running. Further guidance regulations 29 CFR 1910.132-.138; 29 C 138; and 29 CFR 1910.95. Low
Petroleum oil and lubricants (POL) can b disposed of properly. The possibility exis during equipment operations. Ensure spi identified. Adequate ventilation is require maintenance shop. Comply with Shop/In requirements for disposal of hazardous m assessment before conducting training, o assessments assist instructors in identify develops controls, make risk decisions, im supervision and evaluation. Practical Exercise
Inform students of the Learning Step/Act and environmental considerations.
Vickers Inl Hydraulics Manual D01 TSP
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Student Materials:
Color markers Hydraulic simulator boards Student guides Vickers Industrial Hydraulics Manual inserts Pens and pencils
NOTE: If specified equipment is not a similar systems may be substi available a request for wavier a submitted. 1. Explain to the students:
a. Students will work individually wh
b. Students will be divided into 8 gro c. Ensure Students has four, color
d. Each Student or group will have each hydraulic circuit. e. Students will trace the following:
(1) Intake and drain flow in gree (2) Power flow in red. (3) Exhaust flow blue. (4) Relief pressure in purple. f.
Students will interpret pressure g
g. Students will trace and interpret b
h. The instructor will conduct a tenexercise.
Procedures
Note: Show slides #1-13 Problem #1: Retract circuit.
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RETRACT
#5
#9
500 PSI #11 #12
#10
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Note: Show slides #14-22
EXTEND
#5
#9
500 #11 #12
#10
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Problem #2: Retract at controlled speed circuit. Note: Show slides #23-37
RETRACT AT CONTROLLED SPEED

#5
#12
#3
#9
500 PSI #11 #12
#10
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Note: Show slides #38-47
RETRACT AT CONTROLLED SPEED (EXTEND MODE)
#5
#12
#3
#9
500 #11 #12
#10
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Problem #3: Sequencing circuit extending and retracting. Note: Show slides #48-64 (Extending) Note: show slide #65-74 (Retracting)
SEQUENCING CIRCUIT
#5
300 PSI
#6
#2
#9
500 PSI #11 #12 #10
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Problem #4: Pressure reducing circuit extending and retracting. Note: Show slide #75-87 (Extending) Note: Show slide #88-95 (Retracting)
PRESSURE REDUCING CIRCUIT

#5
#12
200 PSI
#2 #12
#4
500 PSI
#9
#11
#10
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Problem #5: Rotary drive with speed control. Note: Show slide #96 (Motor)
ROTARY DRIVE WITH SPEED CONTROL
#8
#9
500 PSI #11 #12 #3 #10
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Administer quiz. Ensure each student has the appropriate copy of the Practical Exercise sheet.
NAME____________________________________ Students # __________
#5 # 12A
200 PSI
#4
#2 300 PSI #9
#6 # 12B # 10
500 PSI # 11
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1. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER FOUR? 1. 2. 3. 4. PRESSURE SEQUENCE VALVE PRESSURE RELIEF VALVE PRESSURE REDUCING VALVE PRESSURE UNLOADING VALVE
2. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER ELEVEN? 1. 2. 3. 4. PRESSURE SEQUENCE VALVE PRESSURE RELIEF VALVE PRESSURE REDUCING VALVE PRESSURE UNLOADING VALVE
3. WHAT TYPE OF PRESSURE CONTROL VALVE IS VALVE NUMBER SIX? 1. 2. 3. 4. PRESSURE SEQUENCE VALVE PRESSURE RELIEF VALVE PRESSURE REDUCING VALVE PRESSURE UNLOADING VALVE
4. WHAT TYPE OF CONTROL VALVE IS VALVE NUMBER NINE? 1. 2. 3. 4. PRESSURE CONTROL DIRECTION CONTROL VOLUME CONTROL SOLENOID CONTROL
5. WHAT IS THE MAX PRESSURE READING GAUGE NUMBER 12B WILL READ WHEN THE CYLINDERS ARE FULLY EXTENDED? 1. 2. 3. 4. 300 PSI 500 PSI 200 PSI 0 PSI
6. WHAT IS THE MAX PRESSURE READING GAUGE NUMBER 12A WILL READ WHEN THE CYLINDERS ARE FULLY EXTENDED? 1. 2. 3. 4. 300 PSI 500 PSI 200 PSI 0 PSI
7. WHAT IS THE PRESSURE READING AT GAUGE12B WHILE CYLINDER TWO IS EXTENDING? 1. 2. 3. 4. 300 PSI 500 PSI 200 PSI 0 PSI
8. WHICH CYLINDER WILL EXTEND FIRST? 1. 2. 3. 4. CYLINDER NUMBER TWO CYLINDER NUMBER FIVE BOTH CYLINDERS AT THE SAME TIME NEITHER CYLINDER WILL EXTEND
9. WHAT COMPONENT IS ITEM NUMBER TEN?
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1. 2. 3. 4.
UNIDIRECTIONAL MOTOR VARIABLE DISPLACEMENT PUMP FIXED DISPLACEMENT MOTOR FIXED DISPLACEMENT PUMP
10. WHAT TYPE OF RESERVOIR IS SHOWN? 1. 2. 3. 4. PRESSURIZED OPEN VENTED CLOSED
11. WHAT TYPE OF CYLINDER IS CYLINDER NUMBER FIVE? 1. 2. 3. 4. VAIN TYPE SINGLE ACTING PISTON DOUBLE ACTING BALANCED DOUBLE ACTING UNBALANCED
12. VALVE NUMBER FOUR HAS A DASHED LINE THAT GOES TO A RESERVOIR SYMBOL, THIS LINE IS A? 1. 2. 3. 4. COMPONENT LINE PILOT LINE RETURN LINE DRAIN LINE
13. VALVE NUMBER FOUR HAS A DOTTED LINE THAT GOES TO AN ENVELOP THIS LINE REPRESENTS A? 1. 2. 3. 4. COMPONENT LINE PILOT LINE RETURN LINE DRAIN LINE
14. HOW MANY POSITIONS DOES THE DIRECTIONAL CONTROL VALVE HAVE? 1. 2. 3. 4. SIX THREE FIVE FOUR
15. A DOTTED BOX AROUND VALVE NUMBER SIX REPRESENTS A? 1. 2. 3. 4. CONTROL VALVE TWO ITEMS IN ONE VALVE COMPONENT ENCLOSURE PILOT OPERATED POPPET VALVE
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10D01PE2 Problem One:
RETRACT
#5
#9
500 PSI
500 PSI
#12
#11
#10
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Problem two:
RETRACT AT CONTROLLED SPEED

#5
#12
500PSI
#3
#9
500 PSI
500PSI
#11 #12
#10
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Problem Three:
SEQUENCING CIRCUIT
#5
300 PSI
#6
#2
#9
500 PSI #11 #12 #10
300 PSI 500 PSI
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Problem Four:
PRESSURE REDUCING CIRCUIT

#5
500 PSI
#12
200 PSI
#2 #12
200 PSI
#4
500 PSI
#9
#11
#10
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Problem Five:
ROTARY DRIVE WITH SPEED CONTROL
#8
#9
500 PSI #11 #12 #3
0-100 PSI
#10
Quiz:
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NAME____________________________________ Student # __________
#5 # 12A 200 PSI #4
#2
300 PSI
#9
#6 # 12B # 10
500 PSI # 11
Question # 1 Question # 2 Question # 3 Question # 4 Question # 5 Question # 6 Question # 7 Question # 8
Answer #3 Answer #2 Answer #1 Answer #2 Answer #2 Answer #3 Answer #1 Answer #2
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Question # 9 Question # 10 Question # 11 Question # 12 Question # 13 Question # 14 Question # 15
Answer #4 Answer #3 Answer #4 Answer #4 Answer #2 Answer #2 Answer #3
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Charge an Accumulator. 62B10D01 version ADT / Hydraulic Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. To be a good mechanic, experience on various items of equipment and systems are required. Part of that experience is training and hands-on practice. Some systems may be complicated or have multiple functions with multiple components involved.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 5) At the completion of this lesson, you [the student] will: Action: Charge an Accumulator.
Motivator
Safety Requirements
Risk of skin and eye injury exists while working with pressurized nitrogen and hydraulic fluid. Students will Personal Protective Equipment (PPE) and point hoses away from their body when working with nitrogen at all times. Use three points of contact when mounting or dismounting equipment. Remove all jewelry to include ID tags and wedding bands when working on equipment. In case of eye contact with hydraulic fluids, eyewash will be used immediately. Ensure regulator is backed out prior to starting task. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low Petroleum oil and lubricants (POL) can be hazardous to the environment if not disposed of properly. The possibility exists for the spillage of fuel, oil, and antifreeze during equipment operations. Ensure spill kits are available and there location identified. Adequate ventilation is required during equipment operations in the maintenance shop. Comply with Shop/Installation SOP/Operations order requirements for disposal of hazardous materials. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation.. Inform students the critical task repair a hydraulic accumulator will be evaluated during this practical exercise. Inform students of the Learning Step/Activity requirements. State the action, safety, and environmental considerations.
Evaluation
Instructional Lead-In Resource Requirements
D01 TSP
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Eye Protection
Student Materials:
Actuator Accumulators Charging Device with nitrogen TMDE General mechanics tool kit Special tools Eye Protection Coveralls Student guide
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. At this station you have an item of equipment with an accumulator requiring gas charging. You have been instructed by your supervisor to charge the accumulator and return the item of equipment to operational status. 1. Explain to the students: a. Students will be divided into eight groups. b. Each student will have forty minutes to charge the accumulator. c. Each person in the team will be given an opportunity to charge the accumulator.
d. The instructor will conduct a ten-minute review with the students and the instructor upon completion of the exercise. e. Ensure each group has nitrogen tank, charging device, accumulator, 3/4" wrench, 11/16" wrench and TM. f. If liquid nitrogen contacts the skin, students should flush the affected areas immediately with plenty of tepid water to reduce the freezing of tissue. Do not apply direct heat or rub frozen area. Clothing contaminated with liquid nitrogen should be removed immediately.
Procedures
1. Follow the steps in the TM. 2. Insure all safety procedures are followed and eye protection and coveralls are worn.
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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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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10D01PE3 Student should have followed all safety procedures, worn eye protection and coveralls and charged the accumulator IAW the applicable references. The accumulator should hold the correct PSI according to the temperature chart in the applicable reference.
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Replace, Test, and Adjust Hydraulic Control Valves and Pumps. 62B10D01 version ADT / Hydraulic Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. To do the most effective job possible, the mechanic who works on equipment with hydraulics must know the components of a hydraulic system. Two of the most important and most complex components are the pump and valves.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 6) At the completion of this lesson, you [the student] will: Action: Replace, Test, and Adjust Hydraulic Control Valves and Pumps.
Motivator
Safety Requirements
Risk of burns, skin and eye injury exists while working with pressurized fluids. Students will wear Personal Protective Equipment (PPE), and relieve hydraulic pressure when working with hydraulic systems at all times. Risk of injury and damage to equipment exists while students operate equipment. Ensure personnel are clear and TMDE is setup IAW the applicable TM prior to starting equipment. Use three points of contact when mounting or dismounting equipment. Remove all jewelry to include ID tags and wedding bands when working on equipment. In case of eye contact with hydraulic fluids, eyewash will be used immediately. Use caution around moving parts. Students will be provided and required to wear PPE while equipment is running. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low Petroleum oil and lubricants (POL) can be hazardous to the environment if not disposed of properly. The possibility exists for the spillage of fuel, oil, and antifreeze during equipment operations. Ensure spill kits are available and there location identified. Adequate ventilation is required during equipment operations in the maintenance shop. Comply with Shop/Installation SOP/Operations order requirements for disposal of hazardous materials. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Performance evaluation. Inform students of the learning step/activity (L/S/A) requirements. State the action, safety, and environmental considerations.
Evaluation Instructional Lead-In Resource Requirements
TM 5-2420-224-34
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TM 5-2350-262-20-2 TM 5-2350-262-10 TM 5-3805-262-34 TM 5-3805-261-34 D01 TSP Eye Protection

Student Materials:
Color markers Hydraulic simulator boards TM 5-2420-224-34 TM 5-2350-262-20-2 TM 5-2350-262-10 TM 5-3805-262-34 TM 5-3805-261-34 TMDE Eye protection Coveralls TM readers Calculator Pens and pencils Student guides
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. 1. Show students cavitation and aeration in one group.
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2. Explain to the students: a. They will be divided into teams of four. b. Each team will have two and a half-hours to correct the malfunction. c. Each person in the team will be given an opportunity to correct the malfunction.
d. Stations will be done in round robin style. e. The instructor will conduct a ten-minute review with the teams and the instructor upon completion of each exercise. f. g. The instructor will control team movement. Ensure each site has tools, TMDE, TMs, setup and available.
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 a FLU 419 (SEE). Your Maintenance chief/ Supervisor has provided you with a new backhoe/crane pressure relief valve and instructed you to replace it. After you replaced the valve you operated the equipment and the backhoe would not go into or out of transport position. You have TMDE, special tools and all applicable TMs. Follow all safety procedures and wear eye protection and coveralls. Using the applicable TMs, replace the backhoe/crane pressure relief valve. Connect the appropriate test equipment to the item of equipment with the appropriate connector(s) and adjust the valve. Isolate the
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malfunction using the referenced diagnostic tests. When the malfunction has been correctly diagnosed, take the appropriate action to correct 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. Your supervisor tells you to remove the old pump and replace it. You have TMDE, special tools and all applicable TMs. Follow all safety procedures and wear eye protection and coveralls. Using the applicable TMs; Replace the pump, connect the appropriate test equipment to the item of equipment with the appropriate connector(s) and adjust the 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 a MW 24 C LOADER with slow or hard steering, TMDE, and special tools with all applicable TMs and necessary maintenance forms. Follow all safety procedures and wear eye protection and coveralls. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic tests. When the malfunction has been correctly diagnosed, take the appropriate action to correct it. 4. Problem #4: The hydraulic system not functioning properly C130 (GRADER). At this station you are in an Organizational Maintenance environment. You have a C 130 Grader with the hydraulic system not functioning properly, TMDE, and special tools with all applicable TMs. Follow all safety procedures and wear eye protection and coveralls. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic tests. When the malfunction has been correctly diagnosed, take the appropriate action to correct it. 5. Instructor will assist students as needed.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10D01PE4 Problem One: The student should have followed all safety procedures and worn eye protection and coveralls. Corrected the fault IAW the TM. Replaced the pressure relief valve and adjusted the relief valve to 2450 psi. Problem Two: The student should have followed all safety procedures and worn eye protection and coveralls. Corrected the fault IAW the TM. Adjusted the compensating pump between 2800-2900 psi. Problem Three: The student should have followed all safety procedures and worn eye protection and coveralls. Corrected the fault IAW the TM. If the pump output in step P was less than 23 GPM, the students should have told the instructor they needed to check the lines between the reservoir and pump. The instructor will tell the students the lines are good. The students should have then told the instructor they would replace the pump. If the pump output in step P was more than 23 GPM and step R was less than step P, the students should have found the efficiency rating of the pump. If the rating was below 75%, the students should have then told the instructor they would replace the pump. If the rating was above 75% the students should have told the instructor they would perform step 4. Problem Four: The student should have followed all safety procedures and worn eye protection and coveralls. Corrected the fault IAW the TM. With the levers in the hold position, if the gage read below 2150 psi, the student should have adjusted the pump or the combination valve. With the levers held in the forward and back position, if all readings where below 3550 psi, the student should have adjusted the combination valve or pump. If only one lever reading was correct and the rest were low, replaced the check valve in the one with the correct reading. If only one position reading was low, replaced the resolver valve.
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POWER TRAIN SYSTEMS

PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10E01 version ADT PRACTICAL EXERCISE SHEET 62B10E01 PE1
Perform Power Shift Transmission Troubleshooting, Repair, and Adjustments 62B10E01 version ADT / Power Train Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. In order to be a competent construction equipment repairer you must understand and be able to perform power shift transmission troubleshooting, repair and adjustments. During this practical exercise you will be introduced to some the techniques used to do this.
Motivator
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 3) At the completion of this lesson, you [the student] will: Action: Perform Power Shift Transmission Troubleshooting, Repair, and
Adjustments.
Safety Requirements
There is a possibility of injury while lifting heavy objects during this lesson. Use proper lifting techniques and lifting devices. Remove all jewelry to include ID tags and wedding bands when working on equipment. Use caution around moving parts. You will wear eye protection while working around equipment. You will be provided and required to wear aural protectors while equipment is in operation. Follow all safety procedures. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95.
Low There is a possibility of environmental contamination by petroleum oil, lubricants, fuel, and cleaning solvents. You will be briefed on the proper disposal of POL products and how to properly clean up spills prior to each practical exercise. Ensure spill kits are available and there location identified. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Inform the students that the critical task of repair a clutch assembly will be evaluated during this practical exercise.
Evaluation
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NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson. Explain to students: 1. Safety is a top priority and will be monitored and enforced throughout this practical exercise. 2. This practical exercise is 8 hours long and will consist of four stations with multiple requirements. 3. 4. 5. The stations will be conducted in a round robin style. You will be working in groups of four, one group per item of equipment. An instructor will start and operate the equipment as required.
6. You must read all safety warnings. 7. A safety briefing will be given at each station pertinent to that station. 8. If you have any questions or problems during this practical exercise contact an instructor prior to continuing.
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20 TM 5-2410-237-34 TM 5-3805-248-14P-2 TM 5-3805-262-20 TM 5-3805-262-24p TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 FOS 40 FOS 54 POL Eye Protection Hearing Protection Caterpillar Dealer Training Course Guide 27 Caterpillar Training Guide 33, Basic Power Shift - Planetary Gearing Caterpillar Training Guide 44, Basic Power Shift - Torque Converters 29 CFR 1910.1200 Hazard Communication 01 Jul 2003 29 CFR 1910.132 Personnel Protective 01 Jul 2003 Equipment General Requirements 29 CFR 1910.133 Eye and Face Protection 01 Jul 2003 29 CFR 1910.136 Foot Protection 01 Jul 2003 29 CFR 1910.138 Hand Protection 01 Jul 2003 29 CFR 1910.95 Occupational Noise 01 Jul 2003 Exposure 29 CFR 1910.1200 Hazard Communication 01 Jul 2003
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29 CFR 1910.132 29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95 29 CFR 1910.1200 29 CFR 1910.132 29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95
Personnel Protective Equipment General Requirements Eye and Face Protection Foot Protection Hand Protection Occupational Noise Exposure Hazard Communication Personnel Protective Equipment General Requirements Eye and Face Protection Foot Protection Hand Protection Occupational Noise Exposure
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
Student Materials:
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20 TM 5-2410-237-34 TM 5-3805-248-14P-2 TM 5-3805-262-20 TM 5-3805-262-24P TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 Eye Protection Hearing Protection Safety Boots Student guides Pens and pencils
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Instructor will: 1. Perform a safety briefing at each station pertinent to that station. 2. 3. Start and operate equipment for students as required. Ensure safety is monitored and enforced throughout this practical exercise.
4. Ensure each station has the applicable Technical Manuals (TMs) and forms as required.
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5. 6.
Ensure all PPE is available at the appropriate stations. Ensure all required tools are at each station.
7. Ensure that each station has a copy of the practical exercise applicable for that station. 8. Assist students as required.
Instructors will inform the students that: At Station One (621B Scrapers) they will locate in the TM and inform the instructor on the procedures for performing a Transmission Shift Point Adjustment IAW TM 5-3805-248-14&P2. No jewelry, id tags, rings will be worn during this PE. Eye protection must be worn while running tests. Hearing protection must be worn while the engine is running. At Station Two (MW24C Loaders) they will perform a Transmission Pressure Check for Slow or Erratic Transmission Shifting IAW TM 5-3805-262-34 and TM 94910-571-12&P. No jewelry, id tags, rings will be worn during this PE. Eye protection must be worn while running tests. Hearing protection must be worn while the engine is running. At Station three (Power Shift Transmission D7G) they will perform a test for TRACTOR MOVES IN FORWARD SPEEDS ONLY IAW TM 5-2410-237-34. No jewelry, id tags, rings will be worn during this PE. Eye protection must be worn while running tests. Hearing protection must be worn while the engine is running. At station four (Power Shift Transmission D7G) YOU WILL DISASSEMBLE, INSPECT AND REASSEMBLE THE CLUTCH PACKS ON THE D7 TRANSMISSION. IAW TM 5-2410-237-34. No jewelry, id tags, rings will be worn during this PE. Eye protection and safety boots must be worn during this PE.
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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 of the 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 TM 5-3805-262-20 locate "Troubleshooting". Under "Transmission", locate "Slow or erratic transmission shifting". 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 erratic transmission 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 N R F H Book Results 135 psi. 135 psi. 135 psi. 125-132 psi. Actual Results
Inform instructor of the results. Shut down and disconnect TMDE when told to do so.
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Station #3: At this station you have D7G Bulldozer that MOVES IN FORWARD SPEEDS ONLY. Using TM 5-2410237-34 locate "Troubleshooting". Under "Symptom Index", locate UNDER TRANSMISSION TROUBLESHOOTING 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 if needed. 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 9-4910-57112&P. Inform instructor of the results. Shut down and disconnect TMDE when told to do so.
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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 the planetary 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 the forward 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 First Forward Second Forward Third Forward First Reverse Second Reverse Third Reverse CLUTCHES ENGAGED 1 and 5 1 and 3 1 and 4 2 and 5 2 and 3 2 and 4
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10E01 PE1 Station #1: Student should have located in TM 5-3805-248-14&P-2, Testing and Adjusting, pg. 2-33 the fault transmission does not make a shift and informed the instructor of the first probable cause. Performed pressure test with TMDE Provided.. Checked the governor oil pressure IAW TM 5-3805-248-14&P2 and test #50 IAW TM 9-4910-571-12&P. Informed the instructor of the results. Station #2: The student should refer to page 2-85 in TM 5-3805-262-34. Inform the student that the transmission oil level has been checked and is OK. The Transducer and adapter may already be installed or you may have the students install the adapter. The student should properly hook up the TMDE using the correct transducer, and perform a OFF-SET Test. Operate the equipment for the student. The student should be instructing you what to do IAW the TM. The student should conduct a pressure test IAW TM 9-4910-57112&P. You may stop the test after the first reading or complete all ranges. If the pressure is not 135 psi ask the students what the causes may be, i.e. cold oil, not up to operating temperature, etc.. Station #3: The student should have used TM 5-2410-237-34 to locate "Troubleshooting". Under "Symptom Index", located TRACTOR MOVES IN FORWARD SPEEDS ONLY. Informed the instructor of the steps to follow IAW the TM troubleshooting guide. THE INSTRUCTOR WILL HAVE STUDENTS PERFORM TRANSMISSION SHIFT LINKAGE ADJUSTMENT IAW TM 5-2410-237-20 PAGE 5-7. THE INSTRUCTOR WILL HAVE STUDENTS TEST TRANSMISSION PUMP PRESSURE IAW TM52410-237-34 PAGE 7-78. When told to do so performed students PERFORMED PRESSURE TEST WITH TMDE PROVIDED Checked the transmission oil pump pressure IAW TM 5-2410-237-34 and test #50 IAW TM 9-4910-57112&P. Informed instructor of the results.
Station #4: Start at step 24 and HAVE STUDENTS disassemble the transmission down to clutch pack number 5 (Do not disassemble the planetary gears.)RE-ENFORCE THE CLASSROOM TRAINING AS THE STUDENTS ARE DISASSEMBLING THE TRANSMISSION BY POINTING OUT COMPONENTS OF THE CLUTCH PACK AND HOW THEY OPERATE.
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Page 7-43 SHOW STUDENTS HOW TO INSPECT THE CLUTCH PISTON, INNER AND OUTER SEALS AND Inspect the clutch plates according to the technical manual Page 7-51; Reassemble transmission. After reassembly, have students identify clutch packs. SPEED First Forward Second Forward Third Forward First Reverse Second Reverse Third Reverse CLUTCHES ENGAGED 1 and 5 1 and 3 1 and 4 2 and 5 2 and 3 2 and 4
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PRACTICAL EXERCISE SHEET 62B10E01 PE2

Identify differential and axle components and their functions. 62B10E01 version ADT / Power Train Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. In order to be a competent construction equipment repairer you must understand and be able to perform differential and axle troubleshooting, repair and adjustments. During this practical exercise you will be be introduced to some the techniques used to do this.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 6) At the completion of this lesson, you [the student] will: Action: Identify differential and axle components and their functions.
Motivator
Safety Requirements
There is a possibility of injury while lifting heavy objects during this lesson. Use proper lifting techniques and lifting devices. You will be provided and required to wear foot protection. Remove all jewelry to include ID tags and wedding bands when working on equipment. Use caution around moving parts. You will wear eye protection while working around equipment. You will be provided and required to wear aural protectors while equipment is in operation. Follow all safety procedures. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95.
Low There is a possibility of environmental contamination by petroleum oil, lubricants, fuel, and cleaning solvents. You will be briefed on the proper disposal of POL products and how to properly clean up spills prior to each practical exercise. Ensure spill kits are available and there location identified. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Inform the students that during this practical exercise they will be evaluated on the critical tasks of replacing a drive shaft, replacing universal joints, replacing a final drive and replacing a differential. NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson. Explain to students:
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1. Safety is a top priority and will be monitored and enforced throughout this practical exercise. 2. This practical exercise is 5 hours 25 minutes long and will consist of 3 stations with multiple requirements. 3. 4. 5. The stations will be conducted in a round robin style. You will be working in groups of four, one group per item of equipment. An instructor will start and operate the equipment as required.
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20 TM 5-2410-237-34 TM 5-3805-248-14P-2 TM 5-3805-262-20 TM 5-3805-262-24p TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 FOS 40 FOS 54 POL Caterpillar Dealer Training Course Guide 27 Caterpillar Training Guide 33, Basic Power Shift - Planetary Gearing Caterpillar Training Guide 44, Basic Power Shift - Torque Converters 29 CFR 1910.1200 Hazard Communication 01 Jul 2003 29 CFR 1910.132 Personnel Protective 01 Jul 2003 Equipment General Requirements 29 CFR 1910.133 Eye and Face Protection 01 Jul 2003 29 CFR 1910.136 Foot Protection 01 Jul 2003 29 CFR 1910.138 Hand Protection 01 Jul 2003 29 CFR 1910.95 Occupational Noise 01 Jul 2003 Exposure Eye & Hearing Protection
Student Materials:
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20
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TM 5-2410-237-34 TM 5-3805-248-14P-2 TM 5-3805-262-20 TM 5-3805-262-24P TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 Student guides Pens and pencils Eye & Hearing Protection Safety Boots Coveralls
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Instructor will: 1. Perform a safety briefing at each station pertinent to that station. 2. 3. Start and operate equipment for students as required. Ensure safety is monitored and enforced throughout this practical exercise.
4. Ensure each station has the applicable Technical Manuals (TMs) and forms as required. 5. 6. Ensure all PPE is available at the appropriate stations. Ensure all required tools are at each station.
7. Ensure that each station has a copy of the practical exercise applicable for that station. 8. Assist students as required.
Instructors will inform the students that: At station one, (MW24C loader) you will correct excessive drive shaft vibration of the front drive shaft and lubricant leaking from front differential carrier. No jewelry, id tags, rings will be worn during this PE. Eye protection, safety boots and coveralls must be worn while performing this PE. At station two you will replace a differential and axle assembly. No jewelry, id tags, rings will be worn during this PE. Eye protection, safety boots and coveralls must be worn while performing this PE.
At station three, (M9 ACE) you will correct excessive noise or vibration and
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excessive engine vibration. No jewelry, id tags, rings will be worn during this PE. Eye protection, safety boots and coveralls must be worn while performing this PE.
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Procedures
Station #1 At this station you have an MW24C loader with excessive drive shaft (propeller) vibration of the front drive shaft. 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. Answer the instructors questions and wait for further guidance. 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.
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Station #2: At this station you have an axle assembly. Following the instructors guidance, you are to remove an axle shaft, final drive and differential, inspect them per the instructors guidance and replace them.
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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. Answer the instructors questions and wait for further guidance.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10E01 PE2 Station #1: The student should have located "Troubleshooting" on pg. 3-3, and then located "Excessive Drive Shaft Vibration" on pg. 3-109. When told to do so performed steps #1 through #5 IAW the TM troubleshooting guide. Answered the instructors questions and waited for further guidance. Used TM 5-3805-262-34, located "Troubleshooting" and then located "Excessive Drive Shaft Vibration". When told to do so performed steps #1 through #3 for the front axle IAW the TM troubleshooting guide. When told to do so performed steps #1 through #3 for the rear axle IAW the TM troubleshooting guide. Informed the instructor of the results.
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Station #2: Using the applicable manual, the instructor will guide the students through the disassembly of the axle assembly, removing the axle shaft, final drive and differential and replacing the differential, axle and finial drive assembly.
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Station #3: The student should have located "Troubleshooting" in TM 5-2350-262-20-1 and then located "Excessive Noise or Vibration" or "Engine Vibrates Excessively". When told to do so performed steps #1 and #2 IAW the TM troubleshooting guide. Informed instructor what further steps the TM troubleshooting guide lead them to. Answered the instructors questions and waited for further guidance. Removed and installed the driveshaft IAW TM 5-2350-262-20-2.
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PRACTICAL EXERCISE SHEET 62B10E01 PE3

Identify final drive components and their functions. 62B10E01 version ADT / Power Train Systems Introduce the instructors for this practical exercise and inform the students of the subject being covered. In order to be a competent construction equipment repairer you must understand and be able to perform final drive troubleshooting, repair and adjustments. During this practical exercise you will be introduced to some the techniques used to do this.
NOTE: The instructor should inform the students of the following Learning Step/Activity requirements. (TLO Step 8) At the completion of this lesson, you [the student] will: Action: Identify final drive components and their functions.
Motivator
Safety Requirements
There is a possibility of injury while lifting heavy objects during this lesson. Use proper lifting techniques and lifting devices. You will be provided and required to wear foot protection. Remove all jewelry to include ID tags and wedding bands when working on equipment. Use caution around moving parts. You will wear eye protection while working around equipment. You will be provided and required to wear aural protectors while equipment is in operation. Follow all safety procedures. The use of PPE by students and instructors is mandatory during this practical exercise. Further guidance concerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95. Low There is a possibility of environmental contamination by petroleum oil, lubricants, fuel, and cleaning solvents. You will be briefed on the proper disposal of POL products and how to properly clean up spills prior to each practical exercise. Ensure spill kits are available and there location identified. Instructors should complete a risk assessment before conducting training, operations, or logistical activities. Risk assessments assist instructors in identifying potential environmental hazards, develops controls, make risk decisions, implement controls, and insure proper supervision and evaluation. Inform the students that during this practical exercise they will be evaluated on the critical tasks of replacing a final drive, repairing a track, replacing a track, repairing steering brakes and clutches and repairing a winch brake. NOTE: Briefly review the general safety requirements, risk assessments, and environmental considerations associated with this lesson. Explain to students: 1. Safety is a top priority and will be monitored and enforced throughout this
Evaluation
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practical exercise. 2. 3. 4. 5. This practical exercise consists of four stations with multiple requirements. The stations will be conducted in a round robin style. You will be working in groups of four, one group per item of equipment. An instructor will start and operate the equipment as required.
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20 TM 5-2410-237-34 TM 5-3805-248-14P-2 TM 5-3805-262-20 TM 5-3805-262-24p TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 FOS 40 FOS 54 POL Caterpillar Dealer Training Course Guide 27 Caterpillar Training Guide 33, Basic Power Shift - Planetary Gearing Caterpillar Training Guide 44, Basic Power Shift - Torque Converters 29 CFR 1910.1200 Hazard Communication 01 Jul 2003 29 CFR 1910.132 Personnel Protective 01 Jul 2003 Equipment General Requirements 29 CFR 1910.133 Eye and Face Protection 01 Jul 2003 29 CFR 1910.136 Foot Protection 01 Jul 2003 29 CFR 1910.138 Hand Protection 01 Jul 2003 29 CFR 1910.95 Occupational Noise 01 Jul 2003 Exposure Eye and Hearing Protection
Student Materials:
TM 5-2350-262-20-1 TM 5-2350-262-20-2 TM 5-2410-237-20 TM 5-2410-237-34 TM 5-3805-248-14P-2
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TM 5-3805-262-20 TM 5-3805-262-24P TM 5-3805-262-34 TM 9-214 TM 9-4910-571-12&P TM 9-8000 LO 5-3805-261-12 Student guides Pens and pencils Eye & Hearing Protection Safety Boots Coveralls Work Gloves
NOTE: If specified equipment is not available for training equipment with similar systems may be substituted. If similar systems are not available a request for wavier and supporting lesson plans must be submitted. Inform the students the allotted time for this PE is 5.5 hours. Perform a safety briefing at each station pertinent to that station. Start and operate equipment for students as required. Ensure safety is monitored and enforced throughout this Practical Exercise. Ensure each station has the applicable Technical Manuals (TMs) as required. Ensure all PPE is available at the appropriate stations. Ensure all required equipment and tools are at each station. Ensure that each station has a copy of the Practical Exercise sheet pertinent to the station. Assist students as required. Explain to the students that: At station one (621B Scrapers) they will remove, disassemble, inspect, reassemble, and replace the 621B final drive assembly IAW TM 5-3805-24814&P2. No jewelry, id tags, rings will be worn during this PE. Eye protection, safety boots and coveralls must be worn while performing this PE. Work gloves will be worn while removing and reassembling heavy components. At station two (D7G Tractor Full Tracked) they will perform a steering clutch, steering brake, track and winch brake repair IAW TM 5-3805-237-20 and TM 52410-237-34. No jewelry, id tags, rings will be worn during this PE. Eye protection and coveralls must be worn while performing this PE. At Station three (M9 ACE Mock-Ups) they will disconnect and connect a final drive
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assembly IAW TM 5-2350-262-20-1 and TM 5-2350-262-20-2. No jewelry, id tags, rings will be worn during this PE. Eye protection and coveralls must be worn while performing this PE. At station four (M9 ACE) replace and repair a track, remove, classify, and replace a road wheel IAW TM 5-2350-262-20-2. No jewelry, id tags, rings will be worn during this PE. Eye protection, safety boots and coveralls must be worn while performing this PE. Work gloves will be worn while removing and reassembling heavy components. NOTE: An instructor will inform students which road wheel will be removed.
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Procedures
Station #1: At this station you have a 621B Scraper. Using TM 5-3805-248-14&P2 and following the instructors guidance, you will remove, disassemble, inspect, reassemble and replace the final drive assembly.
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Station #2a: At this station you have a D7G tractor, Full Tracked. Using TM 5-3805-237-20 and following the instructor'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.
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Station #3: At this station you have a final drive M9Ace Mock-Up. Following the instructors guidance and TM 52350-262-20-1 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 the unserviceable track component (IAW) TM 5-2350-262-20-2 and follow all warnings and instructors guidance. 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 unserviceable track (IAW) TM 5-2350-262-20-2 and follow all warnings and instructors guidance.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10E01 PE3 Station #1: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully removing, disassembling, inspecting, and reassembling a final drive assembly on a 621B Scraper IAW TM 5-3805-248-14&P2. Station #2: The student should refer to TM 5-3805-237-20 and following the instructor's guidance, performed a track winch brake, steering brake, and steering clutch Linkage adjustment.
Station #3: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully disconnecting and reconnecting a final drive assembly on an M9 ACE Mock-Up IAW TM 5-2350-262-20-2. Station #4: The student should refer to TM 5-2350-262-20-2, page 4-766, outer road wheel replacement. Following the instructors guidance and the instructions in the TM, the student should remove and replace one of the road wheels. The instructor will choose which road wheel to remove.
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BRAKE SYSTEMS
PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10F01 version ADT PRACTICAL EXERCISE SHEET 62B10F01PE1
Correct an Air Brake System Malfunction. 62B10F01 version ADT / Brake Systems
Introduction of the instructor and the lesson to
A construction equipment repairer must have a brake system malfunctions in order to be effec environment.
NOTE: The instructor should inform the students o requirements. (TLO Step 2)
At the completion of this lesson, you [the student] w Action: Correct Air Brake System Ma Safety Requirements
Risk of skin and eye injury exists while working eye and foot protection when working with bra when mounting or dismounting equipment. Re wedding bands when working on equipment. eyewash stations will be identified and demons contact with brake fluids, an eye wash will be u moving parts. You will be provided and require equipment is running. The use of Personal pro and instructors is mandatory. Further guidanc OSHA regulations 29 CFR 1910.132-.138; 29 and 138; and 29 CFR 1910.95. Low
There is a possibility of environmental contam and cleaning solvents. You will be briefed on t how to properly clean up spills prior to each pr available and there location identified. Instruct before conducting training, operations, or logis instructors in identifying potential environmenta decisions, implement controls, and insure prop
Evaluation
Inform the students that during this practical e following critical tasks: Repair and replace a pressure gauge.
NOTE: Allow one to two minutes for th
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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 9-2323-211-20-3 w/ch 1 TM 9-2320-211-20-3-2 TM 9-8000 F01 TSP Necessary maintenance forms
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 Necessary maintenance forms
Pens and pencils PPE
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NOTE: If specified equipment is not availa similar systems may be substituted. If request for wavier and supporting less 1. Explain to the students:
a. They will be divided into groups of fou
b. Each group will be given an opportunity to c 2. Instructors guidance
a. Ensure each station has the applicable
b. Ensure all PPE is available at the appr
Ensure all stations have appropriate materials
Procedures
Practical Exercise #1, Problem #1:
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At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with low air pressure, TMDE, special tools, all applicable TMs, and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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Practical Exercise #1, Problem #2: At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with high air pressure, TMDE, special tools, all applicable TMs, and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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Practical Exercise #1, Problem #3: At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with decreasing air pressure, TMDE, special tools, all applicable TMs and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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Practical Exercise #1, Problem #4: At this station you have an item of construction equipment with not enough difference between cut-in and cut-out pressure, TMDE, special tools, all applicable TMs, and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10F01PE1 Practical Exercise #1, Problem #1: There are no specific solutions associated with this PE station. The purpose of this PE is for the student to gain proficiency in troubleshooting air brake system malfunctions, and correcting those problems within realistic maintenance environments. NOTE: Low air pressure in the air brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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Practical Exercise #1, Problem #2: There are no specific solutions associated with this PE station. The purpose of this PE is for the student to gain proficiency in troubleshooting air brake system malfunctions, and correcting those problems within realistic maintenance environments. NOTE: High air pressure in the air brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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Practical Exercise #1, Problem #3: There are no specific solutions associated with this PE station. The purpose of this PE is for the student to gain proficiency in troubleshooting air brake system malfunctions, and correcting those problems within realistic maintenance environments. NOTE: Decreasing air pressure in the air brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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Practical Exercise #1, Problem #4: There are no specific solutions associated with this PE station. The purpose of this PE is for the student to gain proficiency in troubleshooting air brake system malfunctions, and correcting those problems within realistic maintenance environments. Not enough difference between cut-in and cut-out pressure in the air brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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PRACTICAL EXERCISE SHEET 62B10F01PE2

Correct an Hydraulic Brake System Malfunctio 62B10F01 version ADT / Brake Systems
At the completion of this lesson, you [the student] w Action: Correct Hydraulic Brake Syst Safety Requirements
Risk of skin and eye injury exists while working eye and foot protection when working with bra when mounting or dismounting equipment. Re wedding bands when working on equipment. eyewash stations will be identified and demons contact with brake fluids, an eye wash will be u moving parts. You will be provided and require equipment is running. The use of Personal pro and instructors is mandatory. Further guidanc OSHA regulations 29 CFR 1910.132-.138; 29 and 138; and 29 CFR 1910.95. Low
There is a possibility of environmental contam and cleaning solvents. You will be briefed on t how to properly clean up spills prior to each pr available and there location identified. Instruct before conducting training, operations, or logis instructors in identifying potential environmenta decisions, implement controls, and insure prop
Evaluation
Inform the students that during this practical ex following critical tasks: Replace a master cylin replace brake lines.
NOTE: Allow one to two minutes for the le NOTE: Introduce the students to the UMT
TM 5-3805-248-14&P2
TM 5-3805-248-14&P1
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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 9-2323-211-20-3 w/ch 1 TM 9-2320-211-20-3-2 TM 9-8000 F01 TSP Necessary maintenance forms
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 Necessary maintenance forms Pens and pencils
NOTE: If specified equipment is not availa similar systems may be substituted. If request for wavier and supporting less
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1. Explain to the students:
b. Each group will be given an opportunity to c 2. Instructors guidance
a. Ensure each station has the applicable
b. Ensure all PPE is available at the appr
Ensure all stations have appropriate materials
Procedures
Practical Exercise #2, Problem #1:
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At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with air in the hydraulic brake lines, special tools, all applicable TMs, and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the correct referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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Practical Exercise #2, Problem #2: At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with a faulty hydraulic brake master cylinder, special tools, all applicable TMs, and necessary maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the recommended referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10F01PE2 Practical Exercise #2, Problem #1: There are no specific solutions associated with this PE station. The purpose of this PE is for the student to gain proficiency in troubleshooting hydraulic brake system malfunctions, and correcting those problems within realistic maintenance environments. NOTE: Air in a hydraulic brake system is indicative of several possible problems or faulty components. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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Practical Exercise #2, Problem #2: Replace the master cylinder following the step by step instructions in the applicable TM. Return the item of equipment to operational status in accordance with the applicable TM. The purpose of this PE is for the student to gain proficiency in correcting hydraulic brake system malfunctions within a realistic maintenance environment.
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PRACTICAL EXERCISE SHEET 62B10F01PE3

Correct Assisted Brake System Malfunctions. 62B10F01 version ADT / Brake Systems
At the completion of this lesson, you [the student] w Action: Correct Assisted Brake Syste Safety Requirements
Risk of skin and eye injury exists while working eye protection when working with brake system mounting or dismounting equipment. Remove wedding bands when working on equipment. eyewash stations will be identified and demons contact with brake fluids, an eye wash will be u moving parts. You will be provided and require equipment is running. The use of PPE by stud Further guidance concerning PPE can be foun 1910.132-.138; 29 CFR 1910.132-.133; 29 CF 1910.95. Low
There is a possibility of environmental contam and cleaning solvents. You will be briefed on t how to properly clean up spills prior to each pr
Evaluation
Inform the students that during this practical e following critical tasks: Replace brake pads, re caliper and repair and replace an air brake saf
NOTE: Briefly review the general safety req environmental considerations associat Explain to the students:
b. Each person in the group will be given malfunction. c.
Stations will be done in round robin sty
d. The instructor will conduct a ten minut completion of the exercise.
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e. At Station One you will be required to malfunction. f.

At Station Two you will be required to r malfunctions.
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 9-2323-211-20-3 w/ch 1 TM 9-2320-211-20-3-2 TM 9-8000 F01 TSP Necessary maintenance forms
TM 5-3805-248-14&P1
Hearing Protection Eye Protection 29 CFR 1910.1200 Hazard Communication 29 CFR 1910.132 Personnel Protective Equipment General Requirements 29 CFR 1910.133 Eye and Face Protection 29 CFR 1910.136 Foot Protection 29 CFR 1910.138 Hand Protection 29 CFR 1910.95 Occupational Noise Exposure
Student Materials:
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
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
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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 Eye Protection Coveralls Rubber gloves Work gloves
Hearing Protection
NOTE: If specified equipment is not availa similar systems may be substituted a request for wavier and supporting
a. Ensure each station has the applicable required.
b. Ensure all PPE is available at the appr c.
Ensure all required tools are at each s
d. Ensure each station has an adequate forms.
e. Ensure all stations have the appropria
Procedures
Practical Exercise #3, Problem #1: At this station you are in an Organizational Maintenance environment. You have an item of construction equipment with uneven or erratic service brakes, special tools, all applicable TMs, and necessary
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maintenance forms. Using the applicable TMs, connect the appropriate test equipment to the item of equipment with the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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Practical Exercise #3, Problem #2: At this station you are in an Organizational Maintenance environment. You have an item of construction equipment 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 the appropriate connector(s). Isolate the malfunction using the referenced diagnostic 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 major components will be correctly annotated on the necessary maintenance forms.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10F01PE3 Practical Exercise #3, Problem #1Solution: Correct brake malfunction IAW applicable TM NOTE: Ueven or erratic service brakes in an air/hydraulic brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario
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Practical Exercise #3, Problem #2Solution: Correct brake malfunction IAW applicable TM NOTE: Poor braking action in an air/hydraulic brake system is indicative of several possible problems. The problems will be induced by the instructor at random, and may consist of a fault the student cannot repair in the training scenario.
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PMCS
PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10G01 version ADT PRACTICAL EXERCISE SHEET 62B10G01PE1
Components of the BDAR Maintainer Kit
62B10G01 version ADT / Preventive Maintenance C
Introduction of the instructors and the lesson topic t
Battlefield Damage Assessment and Repair (BDAR day battlefield. As a Construction Equipment Repa repair a piece of equipment as quickly as possible in must know what to use and how to use it to repair th Maintainer Kit will provide you with the basic materia
NOTE: The instructor should inform the students of the f requirements. (TLO Step 4)
At the completion of this lesson, you [the student] will: Action: Employ Components of the BDAR Safety Requirements
Maintain 3 points of contact while mounting and dis Follow all safety procedures during this lesson. You equipment is in operation. You will wear eye and fo equipment. The location and use of emergency eye demonstrated to students. In case of eye contact w used immediately. All jewelry to include ID tags will practical exercise and performance evaluation. Saf to insure proper safety procedures are followed. Th Equipment (PPE) by students and instructors is ma concerning PPE can be found in OSHA regulations 1910.132-.133; 29 CFR 1910.132 and 138; and 29
Risk Assessment
Low - Review the deliberate risk assessment, perfo it is recorded on appropriate forms, signed by autho posted at the training site(s).
Petroleum oil and lubricants (POL) can be hazardou disposed of properly. The possibility exists for the s solvents during PMCS. Ensure spill kits are availabl Adequate ventilation is required during equipment o Comply with Shop/Installation SOP/Operations orde hazardous materials. Instructors should complete a conducting training, operations, or logistical activitie instructors in identifying potential environmental haz decisions, implement controls, and insure proper su
Practical Exercise
NOTE: Briefly review the general safety require environmental considera 181
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environmental lesson. Explain to students:
considera
a. Safety is a top priority and will be monitored practical exercise. b.
This practical exercise is 1 hour long and w multiple requirements.
(1) The stations will be conducted in a roun
(2) You will be working in groups of four, on
(3) An instructor will walk you through each
(4) You must read all the safety warnings a
(6) A safety briefing will be given at each st
(7) If you have any questions or problems d contact an instructor prior to continuing
c. At each station you will be given various co Kit, a piece of construction equipment with simu requirement to choose the correct Maintainer K
DA PAM 738-750 TM 5-2410-237-10 TM 5-2410-237-20 TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-3805-248-14&P-1 TM 5-3805-248-14&P-2 TM 5-3805-248-14&P-3 TM 5-3805-261-10 TM 5-3805-261-20 TM 5-3805-262-10 TM 5-3805-262-20 LO 5-2410-237-12 LO 5-2420-224-12 LO 5-3805-261-12 LO 5-3805-262-12 TB 43-0211 Scenarios Equipment Inspection and Petroleum, oil, and lubricants (POL) Parts AOAP Sampling bottles
Maintenance Worksheet
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AOAP Sampling tubing G01 TSP VGTs Eye Protection Hearing Protection 29 CFR 1910.1200 Hazard Communication 29 CFR 1910.132 Personnel Protective Equipment General Requirements 29 CFR 1910.133 Eye and Face Protection 29 CFR 1910.136 Foot Protection 29 CFR 1910.138 Hand Protection 29 CFR 1910.95 Occupational Noise Exposure
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
Student Materials:
DA PAM 750-8 TM 5-2410-237-10 TM 5-2410-237-20 TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-3805-248-14&P-1 TM 5-3805-248-14&P-2 TM 5-3805-248-14&P-3 TM 5-3805-261-10 TM 5-3805-261-20 TM 5-3805-262-10 TM 5-3805-262-20 LO 5-2410-237-12 LO 5-2420-224-12 LO 5-3805-261-12 LO 5-3805-262-12 TB 43-0211 Scenarios Equipment Inspection and Maintenance Worksheet AOAP Sampling bottles AOAP Sampling tubing Student guides Pens and pencils Eye Protection Hearing Protection Coveralls Safety Boots Rubber Gloves Rubber Apron
NOTE: Instructors will:
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a. Perform a safety briefing at each station pe
b. Walk the students through the correct BDAR equipment. c.
Ensure safety is monitored and enforced th
d. Ensure each station has the applicable Tec appropriate forms as required. f.
e. Ensure all PPE is available at the appropria g. Ensure all materials are at each station.
Ensure all required tools are at each station
h. Ensure that all stations have a copy of the P student. i. Assist students as required.
NOTE: Briefly review the risk assessments, env evaluation associated with this lesson.
Procedures
Station #1: Requirement #1: At this station you have a FLU419 SEE that has a small hole in the oil pan producing a class III leak. Choose the correct repair component(s) from the maintainer kit and be prepared to explain
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to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation. Requirement #2: At this station you have a FLU419 SEE with a leak in the nonmetallic steering line that is connected between the steering gear and the steering gear pump. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation.
Station #2: Requirement #1: At this station you have a MW24C scoop loader that has a leaking fuel line between the fuel sediment bowl and the secondary filter. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation. Requirement #2: At this station you have a MW24C scoop loader that has a broken air compressor belt. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation.
Station #3: Requirement #1: At this station you have a 621B scraper that has a class III radiator leak. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation. Requirement #2: At this station you have a 621B scraper that has wiring in the engine compartment broken in half. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation.
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Station #4: Requirement #1: At this station you have a 130G Road Grader that has a large hole in the fuel tank. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation. Requirement #2: At this station you also have D7G Bulldozer with a cracked exhaust manifold. Choose the correct repair component(s) from the maintainer kit and be prepared to explain to the instructor why it/they where chosen. Coveralls will be worn. Do not inhale vapors from any container. The exhaust ventilation system will be in operation.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10G01PE1 Station #1: Requirement #1: FLU419 SEE that has a small hole in the oil pan producing a class III leak. Student should have chosen the 9111 Cleaner/Degreaser and the 1291 Metal Plug Stick.
Requirement #2: FLU419 SEE with a leak in the nonmetallic steering line that is connected between the steering gear and the steering gear pump. Student should have chosen the 9111 Cleaner/Degreaser and the Hercu-Stretch Tape.
Station #2: Requirement #1: MW24C scoop loader that has a leaking fuel line between the fuel sediment bowl and the secondary filter. Student should have chosen the correct Fuel Line Fitting. Requirement #2: MW24C scoop loader that has a broken air compressor belt. Student should have chosen the V Belt. Station #3: Requirement #1: 621B scraper that has a class III radiator leak. Student should have chosen Alumaseal Radiator Seal. Requirement #2: 621B scraper that has wiring in the engine compartment broken in half. Student should have chosen the Wing Nut Electrical Connectors.
Station #4: Requirement #1: 130G Road Grader that has a large hole in the fuel tank. Student should have chosen the Environmental Plugs. Requirement #2: D7G Bulldozer with a cracked exhaust manifold. Student should have chosen the 9111 Cleaner/Degreaser, with the 1221 Super E Metal or the 1111 Super Metal.
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PRACTICAL EXERCISE SHEET 62B10G01PE2

Preventive Maintenance Checks and Services (PMC
62B10G01 version ADT / Preventive Maintenance C
Introduction of the instructors and the lesson topic t
Preventive maintenance checks and services (PMC skills and knowledge required to identify the purpos of PMCS, and the intervals for each type. You will l organizational preventive maintenance checks and construction equipment repairer, must perform effec environment.
NOTE: The instructor should inform the students of the fo requirements. (TLO Step 5)
At the completion of this lesson, you [the student] will: Action: Implement organizational prevent
services (PMCS).
Safety Requirements
Maintain 3 points of contact while mounting and dis Follow all safety procedures during this lesson. You equipment is in operation, and you will also wear ey around equipment. All jewelry to include ID tags wil practical exercise and performance evaluation. Saf to ensure you follow proper safety procedures.
Risk Assessment
Low - Review the deliberate risk assessment, perfo it is recorded on appropriate forms, signed by autho posted at the training site(s).
Petroleum oil and lubricants (POL) can be hazardou disposed of properly. The possibility exists for the s solvents during PMCS. Ensure spill kits are availabl Adequate ventilation is required during equipment o Comply with Shop/Installation SOP/Operations orde hazardous materials. Instructors should complete a conducting training, operations, or logistical activitie instructors in identifying potential environmental haz decisions, implement controls, and insure proper su .
Evaluation
Inform the students the following critical tasks will b exercise: Perform a weekly, monthly, quarterly, sem usage service on an item of construction equipmen construction equipment.
NOTE: Briefly review the general safety require environmental considerations associated wi 1. Explain to students:
a. Safety is a top priority and will be monitored
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practical exercise.
b. This practical exercise is 17.6 hours long an multiple requirements.
(1) Each station will be conducted for the e exercise.
(2) The stations will not be conducted in a r
(3) You will be working in groups of four, on (5) You must read all the safety warnings.
(4) An instructor will start and operate the e
(6) A safety briefing will be given at each st
(7) If you have any questions or problems durin instructor prior to continuing.
DA PAM 738-750 TM 5-2410-237-10 TM 5-2410-237-20 TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-3805-248-14&P-1 TM 5-3805-248-14&P-2 TM 5-3805-248-14&P-3 TM 5-3805-261-10 TM 5-3805-261-20 TM 5-3805-262-10 TM 5-3805-262-20 LO 5-2410-237-12 LO 5-2420-224-12 LO 5-3805-261-12 LO 5-3805-262-12 TB 43-0211 Scenarios Equipment Inspection and Petroleum, oil, and lubricants (POL) Parts AOAP Sampling bottles AOAP Sampling tubing G01 TSP VGTs TVT 928 Eye Protection Hearing Protection
Maintenance Worksheet
29 CFR 1910.1200 29 CFR 1910.132
Hazard Communication Personnel Protective Equipment General Requirements
01 Jul 2003 01 Jul 2003
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29 CFR 1910.133 29 CFR 1910.136 29 CFR 1910.138 29 CFR 1910.95 Exposure

Student Materials:
Eye and Face Protection Foot Protection Hand Protection Occupational Noise
01 Jul 2003 01 Jul 2003 01 Jul 2003 01 Jul 2003
DA PAM 750-8 TM 5-2410-237-10 TM 5-2410-237-20 TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-3805-248-14&P-1 TM 5-3805-248-14&P-2 TM 5-3805-248-14&P-3 TM 5-3805-261-10 TM 5-3805-261-20 TM 5-3805-262-10 TM 5-3805-262-20 LO 5-2410-237-12 LO 5-2420-224-12 LO 5-3805-261-12 LO 5-3805-262-12 TB 43-0211 Scenarios Equipment Inspection and Maintenance Worksheet AOAP Sampling bottles Student guides Pens and pencils Eye Protection Hearing Protection Safety Boots Coveralls Rubber Apron Rubber Gloves
Procedures
Station #1:
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Requirement #1: At this station you have a FLU419 SEE that is due an Annual PMCS. Your supervisor has informed you that you will perform the PMCS in accordance with (IAW) TM 52420-224-20-1. Your supervisor advises you to read all safety warnings, cautions, and notes before performing any task. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Annual PMCS. Your supervisor informs you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-2420-224-20-2. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed all repairs inform the instructor and await further instructions. Station #2: Requirement #1: At this station you have a 621B scraper that is due an Annual Service / 2000 Hour PMCS. Your supervisor has informed you that you will perform the PMCS in accordance with (IAW) TM 5-3805-248-14P3. Your supervisor advises you to read all the safety warnings, cautions, and notes before performing any task, to include blocking the bowl and apron when servicing the hydraulic implements. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Annual Service / 2000 Hour PMCS. Your supervisor has now informed you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-3805-24814P3. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed all repairs inform the instructor and await further instructions. Station #3: Requirement #1: At this station you have a D7G tractor that is due a Bi-Annual PMCS. Your supervisor has informed you that you will perform the PMCS, in accordance with (IAW) TM 52410-237-20. Your supervisor advises you to read all safety warnings, cautions, and notes before performing any task. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Bi-Annual PMCS. Your supervisor informs you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-2410-237-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed all repairs inform the instructor and await further instructions.
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Station #4: Requirement #1: At this station you have a D7G tractor that is due a Bi-Annual PMCS. Your supervisor has informed you that you will perform the PMCS in accordance with (IAW) TM 52410-237-20. Your supervisor advises you to read all safety warnings, cautions, and notes before performing any task. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Bi-Annual PMCS. Your supervisor informs you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-2410-237-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed all repairs inform the instructor and await further instructions. Station #5: Requirement #1: At this station you have a 130G Road Grader that is due a Semi-Annual Service / 500 Hour PMCS. Your supervisor has informed you that you will perform the PMCS in accordance with (IAW) TM 5-3805-261-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Semi-Annual Service / 500 Hour PMCS. Your supervisor informs you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-3805-261-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair; ensure anti-articulation pin is in place before servicing. When you have completed all repairs inform the instructor and await further instructions. Requirement #3: You have completed the service, and the TAMMS clerk informs you that this Road Grader needs a hydraulic oil sample. You are given an oil sample bottle. You are to complete the information on the AOAP bottle label, and then take an oil sample. When you have completed this task inform the instructor and await further instructions. Station #6: Requirement #1: At this station you have a MW24C scoop loader that needs an Annual Service / 1000 Hour PMCS. Your supervisor has informed you that you will perform the PMCS in accordance with (IAW) TM 5-3805-262-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each task. When you have completed the service of selected items inform the instructor and await further instructions. Requirement #2: You have completed the Annual Service / 1000 Hour PMCS. Your supervisor informs you that you must repair any deficiencies annotated on the 5988-E, IAW TM 5-3805262-20. Your supervisor advises you to read all safety warnings, cautions, and notes before each repair. When you have completed all repairs inform the instructor and await further instructions.
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SOLUTION FOR PRACTICAL EXERCISE SHEET 62B10G01PE2 Station #1: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing an Annual PMCS on a FLU419 S.E.E. Tractor, and successfully and safely completing all maintenance repairs necessary as annotated on the 5988-E. Station #2: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing an Annual Service / 2000 Hour PMCS on a 621B Scraper, and successfully and safely completing all maintenance repairs necessary as annotated on 5988-E. Station #3: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing a Bi-Annual PMCS on a D7G tractor, full track, and successfully and safely completing all maintenance repairs necessary as annotated on the 5988-E. Station #4: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing a Bi-Annual PMCS on a D7G tractor, full track, and successfully and safely completing all maintenance repairs necessary as annotated on the 5988-E. Station #5: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing a Semi-Annual Service / 500 Hour PMCS, successfully and safely completing all maintenance repairs necessary as annotated on the 5988-E, and successfully taking an oil sample from the engine and completing the equipment data required on the bottle label. Station #6: There are no correct solutions for this Practical Exercise. The sole purpose of this period of instruction is to provide students with the experience of successfully performing a Annual Service / 1000 Hour PMCS, and successfully and safely completing all maintenance repairs necessary as annotated on the 5988-E.
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2005 Us Army Construction Equipment Repairer Instructor&#39;s Guide 193p

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2005 Us Army Construction Equipment Repairer Instructor&#39;s Guide 193p

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62B10 (R) ADT, PHASE 2 CONSTRUCTION EQUIPMENT REPAIRER INSTRUCTOR'S GUIDE

Evaluation Instructional Lead-In

Instructor Materials: TM 9-243 SC 5180-90-N26 Local SOPs

Student guides Pens and pencils

Identify Wiring Schematics 62B10B01 version ADT / Electrical Systems

There are no safety considerations associated with

Evaluation Instructional Lead-In

* TM 9-6140-200-14 * TM 9-8000 * TM 11-6625-3199-14 * FOS 20 * ITRO-B TSP * Wiring schematics

Before presenting this lesson, Divide class in to tw

1. Group #1 will do a PE on learning activity #

2. Group #2 will do a PE on learning activity #

3. After 1 hour the groups will switch for an a

4. Ensure all materials are on hand and in qu

Read and understand B01 TSP prior to conduc

a. Each student is to work individuall

b. Fifteen minutes will be allotted for Exercise. c.

Following Problem #1, five minute solution with the instructor.

d. Fifteen minutes will be allotted for

e. Following Problem #2, five minute instructor to review the solution. f.

Assist students as required.

PRACTICAL EXERCISE SHEET 62B10B01PE 2

Lesson Number / Title Introduction Motivator

safety, and environmental procedure

Evaluation Instructional Lead-In

* FM 11-60 * * * * * 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

Before presenting this lesson, Divide class in to tw

1. Group #1 will do a PE on learning activity #

2. Group #2 will do a PE on learning activity #

3. After 1 hour the groups will switch for an a

4. Ensure all materials are on hand and in qu

Read and understand B01 TSP prior to conduc

(c) Twenty-five minutes will be allotted fo Exercise.

(e) Ten minutes will be allotted for Proble

(f) Following Problem #2, five minutes w review the solution.

(g) Ten minutes will be allotted for Proble

PRACTICAL EXERCISE SHEET 62B10B01PE 3

Explain the importance of being able to properly id system testing.

Evaluation Instructional Lead-In

State the complete safety, risk assessment level, a considerations.

* FM 11-60 * * * * * * * 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

1. Before presenting this lesson, divide the class

2. Group #1 will do a PE on the SPORT or MSD. 3. Group #2 will do a PE on the Multimeter.

4. After 2 hours 15 minutes the groups will switch minutes.

5. Ensure all materials are on hand and in quanti

Read and understand B01 TSP prior to conduc

PRACTICAL EXERCISE SHEET 62B10B01PE 4

Explain the importance of being able to properly tro charging system..

1. Risk of eye injury exists during ba required to wear eye protection wh

2. Risk of hearing injury during equip required to wear hearing protectio

3. Risk of electrical shock exists thro

4. The use of PPE by students and in this practical exercise.

Emergency showers and eyewash stations will use demonstrated.

Evaluation Instructional Lead-In

1. Before presenting this lesson, divi

4. Ensure all materials are on hand a

Assist students as required.

Assist students as required.

PRACTICAL EXERCISE SHEET 62B10B01PE 5

Evaluation Instructional Lead-In Resource Requirements

TM 5-3805-261-20 TM 5-3805-262-20 TSP 62B10B01

DIESEL ENGINE SYSTEMS

Risk Assessment Environmental Considerations

Evaluation Instructional Lead-In

2005 Us Army Construction Equipment Repairer Instructor's Guide 193p

2005 Us Army Construction Equipment Repairer Instructor's Guide 193p

NAME__________________________ Students #

NAME__________________________ Student #