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Heavy Equipment
Heavy Equipment
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Heavy Equipment
Department
Mechanical Technology
Major
Heavy Equipment
Program Description:
This program has been designed to meet the training needs of the local labor market by taking into considerations the National Occupational Skill Standards (NOSS) for heavy equipment "technician" Trade. The training in this program includes general skills in English Language, Mathematics, Physics, as well as Human Communication Skills. Also, the program includes training on basic skills related to heavy equipment systems and components and their operation, and the fundamentals of heavy equipment electrical and electronic systems that would help the trainee in his career. In addition, the program provides specialized skills in the field of heavy equipment mechanics related to maintenance and repair techniques of heavy equipment mechanical components and systems after performing set of technical tests on the heavy equipment. The training on how to set diagnostic strategies for the mechanical faults in heavy equipment would also be given. In Technical Colleges, training on heavy equipment Technology is performed through (1742) contact hours, in addition to (420) hours of cooperative-training in the labor market through cooperation between the colleges and industrial establishments, governmental and private sectors (like heavy equipment dealers) that work fully or partially in heavy equipment sector. The graduate of this program is awarded an associate degree certificate, and expected to work as a technician in civil and military establishments linked to heavy equipment.
General Objective:
This program aims at providing the trainee with hands on skills, experience and necessary information required to exercise work as a technician in the field of heavy equipment.
Detailed Objectives:
By the end of this program the trainee will be able to efficiently perform the following: 1) Follow up safety procedures and instructions on heavy equipment workshops before commencement of any job. 2) Recognize basic heavy equipment systems and components, functions and methods of operation. 3) Use different specialized tools in heavy equipment field to perform necessary tests on heavy equipment systems and components. 4) Use maintenance and service manuals of different heavy equipment models and deal with heavy equipment spare parts. 5) Execute maintenance and repair operations on heavy equipment systems and components with related skills of assembly and disassembly. 6) Set up diagnostic strategies for the mechanical faults in heavy equipment systems and components. 7) Recognize technical terms in the field of heavy equipment mechanics. 8) Deal with new emerging technologies in different heavy equipment systems.
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Heavy Equipment
Mechanical Technology Department Heavy Equipment Section Study Plan Distributed over all Trimesters No 1 2 3 4 5 6 7 Course Code Course Title Islamic Culture -1 No. of Units Prerequisite C.U. L W T C.H. 2 0 0 2 J J J 2 J J J J J J 2 0 4 0 4 4 2 3 4 2 17 0 2 6 0 0 2 1 4 0 0 4 0 4 0 3 2 24 4
ISLM101
First Trimester
COMP 101 Introduction to Computer Applications ENG 103 General English ARAB 101 Arabic Language PHY 115 General Physics MATH113 General Mathematics
VOC 107
J J J 2 J J J 3 J J J 4 J J J 2 19
Vocational Guidance and Excellence Sum Course Title Engineering Drawing Preparatory Workshops Hydraulic Basics Technical English -1
No 1 Second Trimester 2 3 4 5 6
Course Code
4 4 1
2 4 3 9
4 2
6 2 6 2
113 Math
3 16
1 4 26
14 3
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Heavy Equipment
No 1 Third Trimester 2 3 4 5 6
Course Code
Course Title
ISLM 102 Islamic Culture -2 PHY 116 HEQ 171 HEQ 172 HEQ 173 HEQ174 Specialized Physics
115 PHY Hydraulic and HEQ Pneumatic Systems 163 Diesel Engines HEQ 162 Power HEQ Transmission 162 Heavy Equipment HEQ Electricity 162 Sum
5 6 6
6 29
11 16 2
No 1 Fourth Trimester 2 3 4 5
Course Course Title Code HEQ 251 Diesel Engine Fuel Systems HEQ 252 Heavy Duty Brake System HEQ 253 Heavy Equipment Control Systems ENG 264 Technical English 2 HEQ 254 Technical Drawing Sum
Prerequisite HEQ 172 HEQ 162 HEQ 171 ENG 164 164 MEV
10 16
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Heavy Equipment
No 1 Fifth Trimester 2 3 4 5
Course Code
Course Title
MGT Professional Ethics and 101 Communication Skills HEQ Hydraulic and Pneumatic 261 System maintenance HEQ Traction Systems 262 HEQ Heavy Equipment Maintenance 263 &Troubleshooting HEQ Suspension and Steering 264 Systems Sum
PreNo. of Units requisite C.U. L W T C.H. 2 2 2 J J J HEQ 171 HEQ 173 HEQ 162 HEQ 162 4 4 4 5 2 2 2 3 4 4 4 4 6 6 6 7 27
19 11 16
Sixth Trimester
No 1
2162
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Heavy Equipment
Course description: This course includes training in the basics of engineering drawing, the method of using drawing tools, orthographic projection, conversions, symbols, sections and hatching. The course highlights methods of representing details of mechanical parts through engineering drawing by orthographic projection and sections. Identification of drawing symbols and terms are also included.
2 2 4 -
General course objectives: The course aims at providing the trainees with the ability to use engineering drawing to read drawings and understand symbols, it also prepare the trainees to correctly employ the basics and symbols of engineering drawing in representing details of mechanical parts. Detailed Objectives First: Procedural Objectives: The trainees should be able to: 1) Explain the meaning of different lines used in engineering drawing. - Explanation of the meaning of different lines used in engineering drawing - Identification of different symbols used to transfer information - Read engineering drawing and printed sheets B6, E1, E8, E10, E11, E12, G13, H1, H2, I1, I14, I17, K7, K10 Required Performance Specifications Related Tasks
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Heavy Equipment
Second: Auxiliary Objectives (Cognitive and Behavioral): The trainees should be able to: 1) Identify different types of drawing tools used in engineering drawing.
- Identification of the types of drawing tools used in engineering drawing. - Ability to differentiate between the types of projections in engineering drawing. - Comparison of authentic sectioned parts of automotive components with their technical drawings.
B6, E1, E8, E10, E11, E12, G13, H1, H2, I1, I14, I17, K7, K10
Safety Requirements: Compliance with safety instructions found in the engineering drawing hall. Subjects (Theoretical and Practical) Principles of engineering drawing Orthographic projection Symbols and terms Sections and their types E1, E8, E10, E11, E12, H2 Related Tasks - Determine type of transmission - Check differential gears - Check drive axles - Check propeller shaft support bearings - Check universal joints - Check springs
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Heavy Equipment
Detailed Practical Course Hours Content Principles of engineering drawing: Engineering drawing as a language for technicians Tools and equipment used Types of lines Methods of writing figures and numbers Projection methods Distribution of drawing sheet Freehand drawing Scale of drawing (enlargement / reduction) Evaluation Tools
Orthographic projection: Orthographic projection of points, lines and areas Orthographic projection of the first angle Projection symbols Different view projections of bodies Hidden details Applications
12
Dimensions: Introduction Dimensions techniques Reference and dimension lines Arrow line drawing Methods of writing dimensions Writing dimensions on circles (diameters and radii) Applications
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Heavy Equipment
Detailed Practical Course Hours Isometric drawing: 12 - Methods of isometric representation - Representation of circling surfaces and holes - Applications Content Evaluation Tools
Sections and sectioned shapes: The need for sections Section levels Full section and half section Broken out, revolved, removed, and partial section Applications
12
1- James H, "Drafting, technology", Earle Addison-Wesley Publications Co. 2- M.A. Parker & L.J. Dennis, "Engineering drawing Fundamentals', Stanley Theories. 3- 3- Warren J. Luzadder, "Fundamentals of Engineering Drawing', Prentice-Hall, 1986, Ninth Edition. References:
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Heavy Equipment
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Heavy Equipment
Major Code
Heavy Equipment
HEQ 162
Trimester Course Description: In this course the trainees are introduced to the fundamentals of preparatory workshops and engineering measuring, as well as the fundamentals of safety procedures. The trainees are also introduced in this course to the tools and equipment used in the workshop, heavy equipment parts which include; the engine, power train systems, under carriage, driving shafts, differential, suspension and steering, different brake systems and their types and parts Credit Hours (Hour/week) L Contact Hours (Hour/week) W
2 2
General Goal: This course aims to introduce the trainees to the fundamentals of preparatory workshops and engineering measuring, as well as the fundamentals of safety procedures. The trainees are also introduced in this course to the tools and equipment used in the workshop and all heavy equipment parts.
Behavioral Objectives: The trainees should be able to: Understand the fundamentals of preparatory workshops and engineering measuring. Be familiar with the basic safety procedures. Identify the tools and equipment used in the workshop. Be familiar with heavy equipment parts which include different power train systems, suspension and steering, different Brake systems and their types and parts.
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Heavy Equipment
Topics The fundamentals of preparatory workshops and engineering measurement Safety procedures Tools and equipment used in the workshop Heavy equipment parts which include; different power train systems, suspension and steering systems, different brake systems and their types and parts
References:
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Heavy Equipment
Metal forming which includes: filing bending cutting forming Methods of joining metals; which include: joints classification joint riveting joint welding Machine and tool operation basics; which include: types of tools and equipment operating equipment
carry out methods of joining metals; which include joints classifications joints riveting joints welding basic knowledge of operating machines; which include: types of tools and equipment operating equipment
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Heavy Equipment
Tools, machines and equipment used in the workshop all types of filing tools with different smoothing levels all forging tools in all shapes and sizes wrenches and pullers in all shapes and sizes heavy machinery (turning machines for valves, discs, drums . etc) Heavy equipment types. Dumpers. Tractor Scrapers Wheel dozers Backhoes Compactors Wheeled loader Fork lift Graders. Wheeled tractors.
knowledge of correctly using tools, machines and equipment in the workshop knowing how to protect oneself from injuries when using workshop tools, machines and equipment protecting tools, machines and equipment from any harm
The trainees should be able to: Understand basic information to do with heavy vehicles Compare between wheeled and crawler equipments.
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Heavy Equipment
Power train parts, their types and components; which include: friction clutch and its different types hydraulic coupling torque converter automatic gear boxes different types of propeller shafts, connections and bearings back axel unit, its components and importance axels and rods
Identify power train parts, their types and components; which include: friction clutch and its different types hydraulic coupling torque converter different types of propeller shafts, connections and bearings back axel unit, its components and importance axels and rods
Steering and suspension, their types and components; which include: springs, shock absorbers etc control arms, rods, dust boots, ball bearings, etc wheel alignment angles, their types and importance
Identify Steering and suspension, their types and components; which include: springs, shock absorbers etc control arms, rods, dust boots, ball bearing , etc wheel alignment angles , their types and importance
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Heavy Equipment
Track heavy equipment: Under carriage Crawler track Sprocket wheel Idler wheel Track rollers Track tension adjuster system
Identify under carriage components; which include: Crawler track Sprocket wheel Idler wheel Track rollers Track tension adjuster system
The trainees should be able to know the difference between single and tandem wheels.
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Heavy Equipment
Heavy Equipment
161 HEQ
Course description: Vocational Safety at Heavy-Duty Workshops is an important part of the workplace that trainees should be familiar with. This course covers how to wear work clothes, safety gear, choosing and preparing the appropriate workplace, methods of using tools and equipment and their safety, methods of using lifts. The workshop safety section covers the proper methods for getting rid of exhaust gases, proper storing of flammable materials and using fire extinguishers.
2 1 2 -
General course objectives: The course aims to introduce the trainees to Vocational Safety at Heavy-Duty Workshop which is an important part of any workplace. The trainees learn to wear work clothes, safety gear, choosing the proper location for working and preparing it for that, methods of using tools, equipment, their safety, and methods of using lifts. The trainees also learn workshop safety procedures, and proper storing of flammable materials and using fire extinguishers.
Skill Objectives: The trainees should be able to: Know which work clothes and safety gear are most suitable. Know how to choose a suitable location for working and how to prepare it for that. Know how to correctly use tools and operate equipment and their safety, and methods of using lifts. Follow safety procedures inside the workshop (properly get rid of exhaust gases). Properly store flammable materials and use fire extinguishers.
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Heavy Equipment
Subjects (theoretical and practical): Method of wearing work clothes and safety gear Method of choosing a suitable location for working and preparing it for that Method of using and operating tools, equipment and their safety, and methods of using lifts Following safety procedures in the workshop (properly get rid of exhaust gases) Method of storing flammable materials and using fire extinguishers
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Heavy Equipment
Detailed Practical Course Hours Content 1 Clothes: - wearing work clothes - ensure that the clothes are free of any metal parts - wear safety goggles - wear gloves Skill Objectives The trainees should be able to: - Choose the correct work clothes and safety gear for safety, as well as the safety of the car and for the general appearance of the mechanic. - Prepare a suitable place for working on the car. - Ensure that the floor is free of any liquid spills. - Ensure the presence of safety equipment. Related tasks
A1
2 The place: - choosing a proper location for the job - placing the car in the right location for the job - ensure that the floor is free of any liquids spills - ensure the presence of safety equipment
A2
3 Using tools: - Knowing the tools and using the most suitable ones for the job - Taking care of the tools - Ensuring the safety of the vehicle
- Use tools properly to avoid injuries, safe usage and storage of tools. A3
4 Equipment: 4 - Proper usage of equipment - Using the right device - Taking care of the equipment - Use equipment properly to avoid injuries, safe usage and storage of equipment. A4
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Heavy Equipment
5 Lifts: - Learn about lifts and methods of using them - Proper placement of vehicle on the lift - Ensure the stability of the vehicle
- Secure car lifts to ensure the safety of the car, the worker and the workshop. A5
6 Exhaust gases: - Ensure the suction of exhaust gases - Use exhaust gas suction hoses
- Use exhaust gas suction hoses with special equipment to prevent air pollution inside the workshop.
A6
7 Flammable materials: - Store flammable materials in their designated places - Take caution when carrying flammable materials - Ventilation of their storing area - Locking the place
- Store flammable materials in their designated places for the safety of the workshop, the car, and the worker and for general safety.
A7
8 Fire extinguishers: - Learn how to use fire extinguishers and their types - Know the location of the fire extinguishers
A8
9 Manufacturing companys recommendations: - Placing shields on cars while working - Protect car when working on it
- Adhere to manufacturing companys recommendations to protect the car body and the workshop facilities.
A9
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Heavy Equipment
Mechanical Technology
Hydraulic Basics
Course Description: This course includes the study of Pascal's law, Bernoulli principle, force and pressure transmission in hydraulic systems and determining the type of flow with solving some exercises. Also, the course includes the principle properties of compressed air, dealing with the unit used, as well as an introduction to the special devices that convert energy and the devices used in energy control.
General Goal: The general goal is the study of physical properties of pneumatic and hydraulic systems, and to study the basic laws of hydraulic systems.
Behavioral Objectives: The trainees should be able to: Understand the physical properties of hydraulic systems and basic laws of hydrostatics and hydrodynamics. Understand the properties of the hydraulic oils and determine their specifications. Performing the calculation of the pressure loss in the pipes. Be familiar the theory of operation and the structure and know the symbols of pumps, cylinders, hydraulic motors and the directional control valves and the control valves of pressure and flow rate. Understand the basic properties of compressed air as medium used in energy transmission for the purposes of control, and the other necessary specific properties of compressed air. Understand the principles that should be awarded in preparing compressed air, the devices that are used in pneumatic energy conversion, and also the control devices used in pneumatic energy.
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Heavy Equipment
Theoretical and Practical Topics: Definitions: hydraulics hydrostatics hydrodynamics Hydrostatics Pressure force transmission in hydraulic systems Pascal's law Fluid flow kinematics Flow types continuity equation Bernoulli equation Pressure drop Oils properties and types Viscosity - properties classifications testing Symbols of hydraulic components Energy conversion devices (pumps hydraulic drive station) Cylinders and hydraulic motors The physical properties of compressed air The method of preparing compressed air Symbols of hydraulic and pneumatic components
References:
Fluid mechanics and its applications Robert Dogerty Mc-Graw-Hill company. The first training book Manzman and Roxroth.
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Heavy Equipment
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Heavy Equipment
Hydrostatics pressure: Pressure definition Pascal's law Force transmission in hydraulic system Exercises
The trainees should be able to: Define pressure absolute pressure gauge pressure atmospheric pressure the international and practical units of pressure. Express the pressure resulting from external forces (Pascal's law). Understand how the pressure can be increased in hydraulic systems. Describe the forces of transmission in hydraulic systemhydraulic pistons pressure converter. Express pressure in terms of the fluid height. Solve problems to do with: pressure calculations and force, and pressure transmissions in hydraulic systems. B4 B9 H3 H4
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Heavy Equipment
Fluid kinematics Fluid flow: Flow types Reynolds number Continuity equation Equation of motion Bernoulli principle
The trainees should be able to: Describe the types of flow: laminar and turbulent, and know the factors affecting the flow type calculation of Reynolds number in circular pipes solving exercises to determine the type of flow continuity equation and solving its application problems . Understand the kinetic energy to the flowing fluid and how to calculate it calculation of potential and pressure energy. Deduce the energy equation for steady incompressible fluid flow (Bernoulli principle) solving applied problems in calculating the flow rate, force, piston speed, the time taken in advance, and return strokes of the piston determining the relationship between the flow rate, the cross section area and pressure drop determine the work and power of the hydraulic systems Calculations of designing a simple hydraulic circuit used for raising a certain weight through a certain distance by a certain speed; including the power and capacity of the pump and the tank size the types of valves.
B2 B3 B5 C7
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Heavy Equipment
Pressure drop:
Calculations of pressure loss Calculate the pressure drop in in pipes simple pipes for the compressible (gases vapors) and Calculation of loss and flow in incompressible fluids (liquids). pipes Calculate the pressure loss and flow rate in pipes calculations of pressure loss using the relationship between the flow velocities, type of flow according to the approximate formulae. Determine the pressure loss using charts.
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Heavy Equipment
Identify the functions of Functions of the hydraulic oils hydraulic oils and the quality requirements for hydraulic oils. Hydraulic oils characteristics Different expression of Identify the characteristics of hydraulic oil and the viscosity viscosity effect on the leakage and friction Symbols of hydraulic describe the viscosity elements expression be familiar with the different expressions of viscosity absolute and kinematic viscosity and international and practical units of viscosity understand the method of measuring viscosity understand the concept of viscosity index understand the effect of temperature and pressure on viscosity be familiar with the type of hydraulic oils make a suitable hydraulic oil selection after evaluating its different properties (viscosityincompressibility-foam damping ability to separate water and air release- oxidizing resistance durability - freezing point flash point boiling point suitability with the hoses. Be familiar with the incombustible hydraulic liquids and their different groups. Know of maintenance instructions, storage and resistance of hydraulic oils analysis and explaining the meaning of valves symbols, cylinders, and different accessories according the standards 1219 DIN/ISO.
D9 B13 B14
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Heavy Equipment
Physical properties of air: Special unit for compressed air Volume and pressure laws Air laws Relation between the pressurevolume temperature in gases Solving a number of applied exercises
The trainees should be able to: Understand the physical quantities and the special units of the compressed air volume and pressure laws- atmospheric pressure and its measuring units absolute pressure gauge pressure the physical properties and air laws the relationship between pressure volume and temperature in gases solve some applied exercises using the laws taught previously, and convert to the international units SI. J9 J10
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Heavy Equipment
Preparation of compressed air: Humidity concept Using compressed air as a working medium
The trainees should be able to: Understand the concepts of absolute humidity maximum relative humidity degree of saturation determine the air humidity in terms of temperature- solve exercises to calculate condensed water types of flows : laminar and turbulent the mutual effect between the flow rate and pressure advantages of using air as a working fluid describing the methods of air drying knowledge of installing compressed air tanks and water traps and air pipes the principles required in the installation process. Use charts to calculate pipe diameter knowledge of using the charts in calculating the equivalent length for the flow resistance through valves and fittings and how to modify the pipe calculations using charts to determine flow rate knowledge of the pressure filter performance water separator and oiling device and their symbols.
J1 J2 J3 J5 J9 J10
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Heavy Equipment
Measuring the hydraulic The trainees should be able to: pressure through the height of Apply the laws of hydrostatics. the measured liquid
B3 B9 H3 H4
Reynolds process 14
The trainees should be able to: Describe the flow types: laminar and turbulent and knowledge the factors on the types of flow calculating the Reynolds number in circular ducts.
B2 B3 B5 C7
The trainees should be able to: Measure the pressure loss for compressible and incompressible fluids. Measure the flow losses. Measure the pressure and flow rate losses in pipes.
B5 H3 H4
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Heavy Equipment
Major Code
Trimester Course Description: The first part of the course covers batteries, alternators and starting motors. The second part covers the lights, windshield wipers and horns. The course focuses on the new elements introduced in the above mentioned systems and circuits for heavy equipments. The practical part of the course includes many tests as well as disassembly and assembly procedures for those systems and circuits Credit Hours (Hour/week) L Contact Hours (Hour/week) W
3 4 2 4
General Goal: The course is designed to give the trainees the required knowledge of electrical systems and circuits. Also, it enables them to deal practically with heavy equipment electricity.
Behavioral Objectives: The trainees should be able to: Identify different components of electrical systems as well as how they work and affect each other. Understand how to choose the appropriate element for a certain vehicle (i.e. battery, starting motor, etc) Be familiar with to check, remove and install different elements.
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Heavy Equipment
Topics
Basic electrical & electronic components Batteries Charging systems Starting systems Lights Windshield wipers Horns
References:
Diesel Equipment,Vol.I, E.,J., Schulz McGraw-Hill book Company, New York, U.S.A. 1982 Heavy Duty Truck Systems , I., Norman, R., Scharff, J., Corinchock, Delmar Publishers, Albany, N.Y., U.S.A..1992 Modern Farm Power, W., J., Promersberger, D.,W., Priebe , F., E., Bishop, Reston Publishing Company& A Prentice-Hall Company, Reston, Virginia, U.S.A.. 1979
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Heavy Equipment
2-Batteries: Battery duty, elements and classifications Charging and discharging of a battery Battery ratings
Identify battery components and types. Differentiate between battery charging and discharging, as well as how to choose a battery.
2-Charging systems: Charging systems components and circuits Alternator components and operation Regulators components and operation
Identify charging systems components and circuits. Identify alternator components Identify how an alternator produces electricity and how a regulator regulates its output
4-Starting systems: Electrical starting systems (starting motor requirements, components and operation) Hydraulic starting systems Pneumatic starting systems
Choose the appropriate starting motor for a particular heavy vehicle Determine the type of any starting system and its features
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Heavy Equipment
5-Lights: 4 Headlights and taillights systems Turn-signal and emergency lights Stoplights and backup lights
Be familiar with light components and circuits Be aware of light importance for driving safety
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Heavy Equipment
2-Batteries: Application of safety measures Performing battery tests and charging as well as jump starting (case of a 24v system).
Learn how to test a battery in a safe way and charge it, in addition to jump starting a heavy-duty vehicle.
14
3-Charging systems: Completing alternator tests (output test, field current test, etc) Performing alternator disassembly and assembly Applying necessary modifications to produce 24v output.
Determine charging system elements and be able to disassemble and assemble alternator components. Check and test charging systems.
4-Starting systems; Checking and testing electrical starting systems (no-lead test, cranking current test, etc) Carrying out disassembly and assembly operations of starting motors Testing hydraulic and pneumatic starting systems as well as removing and mounting of their important elements
Check, test, disassemble and assemble electrical starting systems as well as hydraulic and pneumatic starting systems.
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Heavy Equipment
10
5-Lights: Performing checks and tests concerning different lights Removing and installing different lights as well as their adjustment
6-Windshield wipers: Carrying out relevant checks and tests, as well as disassembly and assembly steps
7-Horns: Checking and testing horn components Removing and installing horns
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Heavy Equipment
Major Code
Trimester Course Description: This course is designed to provide the trainees with both a theoretical and practical background in the basic operating principals of diesel engines, fuels, and classifications. Practical experience in overhauling, testing, troubleshooting, and tuning of diesel engines. Disassembly, inspection of parts, reassembly, maintenance procedures, and running a diesel engine will also be covered. Auxiliary systems such as lubrication, cooling, intake and exhaust, turbocharger, and blowers will be emphasized. Credit Hours (Hour/week) L W Contact Hours (Hour/week) T
3 4 2 4
4 5
General Goal: The trainees acquire basic knowledge of diesel engines operating theories , parts, classifications, and auxiliary systems. Plus the practical experience in inspecting, fault diagnosing, repair, adjusting, and overhauling diesel engines.
Behavioral Objectives: The trainees should be able to: Explain the fundamentals of diesel engines operating theories, parts, and classifications. Explain cooling, lubrication, and auxiliary systems: such as intake, exhaust systems components and operating theories. Explain heavy duty brake system components as found in heavy equipment. Inspect, repair, and adjust diesel engine systems. Overhaul diesel engines.
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Heavy Equipment
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Heavy Equipment
Topics
Diesel engines fundamentals Four stroke and two stroke cycles Diesel engines classifications Diesel fuel characteristics Cooling, lubrication, intake, and exhaust systems Inspection, repair, and adjustment of engine systems Fault diagnosing, testing, and overhauling diesel engines
References:
Diesel Engine and Fuel Systems, Barry Wellington and Alan Asmus Diesel and Mobile Plant Technology, Clifford M. Tempest
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Heavy Equipment
2-Combustion in compression ignition engines: The stages of combustion Combustion chambers (open combustion chambers, pre-combustion chambers and swirl chambers) Diesel knock Cold starting aids (glow plugs: layout and operation)
Explain the stages of combustion in a compression ignition engine and determine different types of combustion chambers. Explain the phenomena of 'diesel knock', as well as the causes and factors affecting its occurrence. Explain the purpose and operation of glow plugs.
3-Cylinder head and attachments: Intake and exhaust valves (valve seatsvalve guides-injector sleeves) Methods of cylinder head and valve service Recognize cylinder head components and the method of inspection.
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Heavy Equipment
4-Cylinder blocks: Types of cylinder blocks (air cooled and water cooled cylinder blocks) Cylinder liners (dry and wet liners) Cylinder liner wear and measurements Cylinder block service Recognize cylinder block parts and explain different types of cylinder liners and methods of inspection.
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Heavy Equipment
5-Pistons, rings, and connecting rods: Types of pistons-piston cooling Piston pin Piston rings and types Connecting rods Define different types of pistons and connecting rods and their related attachments.
6-Valve timing mechanism: Valve timing Valve train components Camshaft camshaft drives Valve train service Explain valve train components and methods of inspection and timing the valves.
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Heavy Equipment
6-Cooling systems: The importance of cooling Types of cooling system (water and air cooled systems) Cooling system components and operations (radiator-cap-coolantthermostat-water pump-the fantransmission oil cooler) Differentiate between air and water cooled systems. Explain components and operations of air cooled and water cooled systems.
8-Air and exhaust systems: Air intake system in diesel engines Air cleaners (types-construction) Turbochargers (construction and operation) Blowers Air intake troubles Exhaust system Mufflers (types and operation) Explain the components of air intake and exhaust systems, and recognize their faults. Indicate the effect of supercharging on diesel engine performance. Explain turbocharger construction and operation, and its effect on engine power, fuel consumption, and exhaust emissions.
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Heavy Equipment
9-Diesel engine faultfinding, testing and overhauling: Faultfinding (compression testing-diesel exhaust smoke) Diesel engine testing (purpose of testing-engine testing standards) Steps of diesel engine overhauling Inspection and necessary measurements Diagnose, inspect faults, perform testing, and necessary measurements, and explain the steps of diesel engine overhauling.
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Heavy Equipment
2-Cylinder head and valve service: Removal of cylinder head Cleaning cylinder heads Inspection and repair of components (cylinder head face-crack inspectionvalves-valve guides-valve seats-valve springs-injector-seats) Combustion chamber removal Replacement of glow plugs Installing cylinder head to block Inspect and repair cylinder heads and related attachments.
3-Cylinder block service: Cleaning the cylinder block Cylinder liner measurement Inspection of liners (out-of-roundness ovality) Cylinder block bearing alignment Installing cylinder liners
Inspect and repair the cylinder block. Dismantle, install, and inspect cylinder liners.
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Heavy Equipment
Behavioral Objectives The trainees should be able to: Remove, assemble, inspect, and replace crankshafts. Inspect and repair flywheels.
Crankshaft removal Crankshaft apparent inspection and measurements Bent inspection Crack inspection Crankshaft polishing and grinding Replacing crankshaft Inspection of bearings and clearance. Crankshaft oil seals installation Inspection and repair of flywheels Assembling the crankshaft into the block
Removal of pistons Inspection and repair piston components-ring groove Piston dimension measurements Assembling of rings Connecting rod inspection (big and small ends-alignment) Assembly of piston to connecting rod Installing piston and connecting rod assembly Analysing piston and cylinder problems
Remove, inspect, repair, and replace pistons and connecting rods. Disassemble and assemble piston rings. Assemble piston and the connecting rod, and install assembly in block
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Heavy Equipment
Camshaft removal and inspection Inspection of camshaft bearings Inspection of cam followers-pushrodsrocker arms and shaft Camshaft installation Valve clearance adjustment Inspection and replacement of timing belts
Remove, install, inspect, and repair valve train assembly. Adjust valve clearance. Inspect and replace timing belt.
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Heavy Equipment
Oil filters replacement Inspection and repair of oil pump Oil pumps assembly Testing of leakage of oil cooler
9-Intake and exhaust system service: Inspection and repair of air intake system problems Replacement of filters and piping Inspection of turbochargers Repair, assembly and testing turbochargers Disassembly, inspection and repair of air blowers Inspection and repair of exhaust system Inspect and repair intake and exhaust system parts.
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Heavy Equipment
10-Faultfinding and testing diesel engines: Faultfinding and testing diesel engines using special testing apparatus to determine changing of: power-fuel consumption-inlet air pressure-fuel pressure and temperature- exhaust pressure and temperature-engine speed.etc. Engine testing report analysis Diagnose diesel engine faults and analyze test reports.
10
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Heavy Equipment
Major Code
Trimester Course Description: This course covers hydraulic and pneumatic systems. In the beginning, the system types as well as the components and circuits are explained. Then samples of these systems in heavy equipments are presented. The practical part contains a number of tests for systems components (pumps, hydraulic and pneumatic cylinder and motors) in addition to assembly and disassembly procedures Credit Hours (Hour/week) L Contact Hours (Hour/week) W
3 3 1 4
4 5
General Goal: The course aims to enable the trainees to understand different hydraulic and pneumatic systems (component, operation, circuit). Also, it gives them the necessary skills to service these systems.
Behavioral Objectives: The trainees should be able to: Apply the safety measures in dealing with heavy hydraulic and pneumatic systems. Understand component function and system operation. Perform the relevant tests and replacement work. Understand the system particularities of heavy equipment.
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Heavy Equipment
Topics
Basic concepts of hydraulics & pneumatics Hydraulics & pneumatics system types Hydraulic system components Application of hydraulic systems in heavy equipment Design and drawing of hydraulic circuits Pneumatic system components Application of pneumatic systems in heavy equipment Design and drawing of pneumatic circuits
References:
Fluid Power ( Theory & Application) ,J., Sullivan Printice Hall International, Inc., Upper Saddle River, New York, U. S. A., 1998 Fluid Power wit Applications, A.., Esposito, Printice Hall, Columbus, Ohio, U. S. A., 1980 Diesel Equipment, Vol.I &Vol.II, E.,J., Schulz McGraw-Hill book Company, New York, U.S.A. 1982 Moving the Earth ( The Handbook of Excavation), H., L., Nichols, North Castle Books, Greenwich, Connecticut,
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Heavy Equipment
The trainees should be able to: Identify different system components as well as how they work. Note the particular features of heavy-duty hydraulic systems.
Hydraulic systems in heavy equipments (system components and operation for on-high way vehicles and off-high way vehicles)
Criteria of hydraulic circuit design and classification Circuit design procedure for (single and double- acting) hydraulic cylinders
Pneumatic systems in heavy equipments (system components and operation for on-high way vehicles and off-high way vehicles) Criteria of pneumatic circuit design procedure for (single-and double-acting) pneumatic cylinders
- 52 -
Heavy Equipment
1-Determining and servicing hydraulic system components in some heavy equipment: Inspection, testing, mounting, demounting and cleaning of pumps and accumulators
- 53 -
Heavy Equipment
Inspection and testing of compressors Mounting and demounting of some demountable types
4
.
- 54 -
Heavy Equipment
3 4
4 5
Course Description: This course covers the fundamentals of power transmission. The study of mechanical and hydrostatic transmission systems used in heavy equipment, along with disassembly, assembly, inspection, and repair of transmission system.
2 4
General Goal: The course is designed to give the trainees the fundamental knowledge concerned with different methods of power transmission, components of mechanical and hydrostatic transmission systems used in heavy equipment, and methods of inspection and repair of these components.
Behavioral Objectives: The trainees should be able to: Explain methods of power transmission in heavy equipment. Distinguish between different clutches used in power transmission, and explain parts and operation. Explain the hydrostatic circuit of hydrostatic transmission system. Explain the function of the components of hydrostatic transmission system. Explain the function of the components and operation of standard and automatic transmission. Explain the function of drive shafts, joints, and different types of final drives used in heavy equipment. Inspect, repair, and adjust transmission system parts used in different types of heavy equipment.
- 55 -
Heavy Equipment
Topics
Methods of power transmission in heavy equipment Clutches Gear boxes Hydrostatic transmission Drive shafts and final drive Inspection, repair, and adjustment of transmission system parts and joints
References:
- 56 -
Heavy Equipment
2-Clutches: Mechanical clutches (jaw clutch-single and multi-disc friction clutches-clutch linkages) Clutch fault diagnosis Hydraulic coupling Torque converter (single and multistages-oil cooling circuit) Identify the different types of clutches used in heavy equipment and define the parts and operation of each. Faults diagnose clutch parts.
3-Hydrostatic transmission: Hydrostatic circuits Pump to motor drives Piston pump and variable displacement. Swash plate control Explain hydrostatic circuits for hydrostatic transmission systems, and system parts and operation.
- 57 -
Heavy Equipment
5-Drive shafts and final drives: Propeller shaft and joints Differentials (types: single and double reduction carriers-purpose of differential gears and construction) Final drives (types: single and double reduction-planetary final drives) Define the characteristics of drive shafts and the construction of differential carriers and final drives used in heavy equipment.
- 58 -
Heavy Equipment
2-Inspection, repair, adjustment of mechanical clutches: Lubrication Adjustment Free play adjustment Clutch failures Inspection and repair of clutch linkages Clutch removal and disassembly Checking for wear Assembly, installation and adjustment of clutch Determine clutch faults. Disassemble and assemble clutch parts. Install clutch and perform final adjustments.
- 59 -
Heavy Equipment
3- Inspection, repair, adjustment of transmissions: Removal and disassembly of gear boxes Inspection of performance and repair of standard transmission Inspection and repair of automatic transmission (inspection of pressurecontrol valves-oil cooling circuitleakages) Inspection and repair of transfer case and auxiliary gear box Determine faults and repair standard transmissions. Disassemble, assemble and install transmission of the equipment. Inspect and repair automatic transmission. Inspect and repair transfer case and auxiliary gear box.
26
- 60 -
Heavy Equipment
Behavioral Objectives The trainees should be able to: Dismantle, disassemble, inspect, repair and reinstall drive shafts and the final drive assembly of heavy equipment.
12
Inspection and repair of propeller shaft and joints Replacement of joints Replacement of propeller shaft Inspection and repair of differentials Inspection and repair of final drive assembly
- 61 -
Heavy Equipment
Major Code
Trimester Course Description: This course covers study theories, operations and the description of brake systems common to heavy duty equipment. Topics include; air, hydraulic, ABS, and parking brake systems. With emphasis on the practical applications of repair, service, and troubleshooting of various systems. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T
4 5 3 4
General Goal: The course is designed to give the trainees a good grounding in the theories of operation and maintenance of heavy equipment, brake system parts and repair of hydraulic, pneumatic, and parking brake systems.
Behavioral Objectives: The trainees should be able to: Explain the fundamentals of braking and theories of operation. Compare different types of heavy equipment braking systems. Identify heavy duty brake system components as found in heavy equipment. Distinguish between different types of drum and disc brakes. Explain the theories of hydraulic, pneumatic, and parking brake systems. Explain the purpose of Anti-lock Braking System (ABS) and its components. Diagnose, maintain, and repair different parts of heavy equipment brake systems.
- 62 -
Heavy Equipment
Topics
Fundamentals of heavy duty braking Hydraulic brakes Disc brakes Drum brakes Pneumatic brakes Anti-lock braking systems Diagnosis, maintenance and repair of heavy equipment brake systems
References:
- 63 -
Heavy Equipment
Power requirement for braking Stopping distance Coefficient of friction Brake lining friction Brake torque (stopping power) Engine brakes
2-Hydraulic brakes: Master cylinders (single tandem) Brake pipes and hoses Wheel cylinder Brake drums and brake shoes Brake pressure control valves (metering valve-proportional valve-combination valve) Servo brakes Explain hydraulic brake system components and the function of each part.
3- Disc brakes: 4 Floating caliper disc brakes Fixed caliper disc brakes Multi-disc brakes Explain the construction of disc brakes and multi-disc brakes used in heavy equipment.
- 64 -
Heavy Equipment
5-Pneumatic brakes: 13 Basic air brake system Brake chamber Air compressors Brake valves (application valve-hand application valve-dual application valve) Air brake reservoirs Dual air brake system Tractor-trailer brake systems Parking brakes Parking brake control valve Identify air brake and parking brake structural components as found in heavy equipment. Explain the operation of different types of air brakes and tractortrailer brake system.
6-Anti-lock braking systems: Wheel speed sensors Controllers Pressure protection valves Explain the purpose of anti-lock brake system and types. Determine components of ABS Explain the operation of each component.
- 65 -
Heavy Equipment
Dismantling, checking, repair, and reinstallation of hydraulic master cylinder Bleeding air from hydraulic system. Inspection and replacement of brake shoes and pads Dismantling, disassembly, inspection, assembly, and reinstallation of wheel cylinder Inspection of leakage and replacement of brake hoses Inspection, replacement, and reinstallation of hub Checking brake valves
Know how to identify hydraulic system parts. Check and repair the master cylinder. Inspect, repair, and replace hydraulic brake system parts. Bleed air from the system.
- 66 -
Heavy Equipment
Inspection, repair, and replacement of brake discs Dismantling floating and fixed calipers Disassembly and assembly of caliper. Cleaning, inspecting and repair caliper Reinstalling caliper Servicing and maintenance of multi-disc brakes
- 67 -
Heavy Equipment
Behavioral Objectives The trainees should be able to: Inspect, adjust and repair cam and wedge brakes.
Inspection, adjustment and repair of cam brake Inspection, adjustment and repair of wedge brake
5-Inspection and repair of brake booster 4 Inspect and repair a brake booster.
Oil power brake parts identification Inspection and repair of brake pump
14
Pneumatic brake system parts Inspection of brake air reservoir and leakage in brake supply lines Inspection, repair, and test of air compressor Inspect and test brake pressure regulator valve Adjust air pressure in system Repair air brake chamber Maintenance and repair of brake valves Adjustment and repair of parking brakes
Inspect, adjust, and repair brake system components. Adjust air pressure in a brake system.
- 68 -
Heavy Equipment
Behavioral Objectives The trainees should be able to: Inspect, maintain, and repair antilock brake systems and components.
Testing, adjusting and repair of antilock brake system Inspection, replacement of ABS sensors Inspection of ABS connections Inspection and replacement of controller
- 69 -
Heavy Equipment
Major Code
Trimester Course Description: This course presents the study of different types of diesel fuel injection systems and components including; fuel tank, supply pump, injection pump, injectors, and electronic diesel controls. The practical sessions include; methods of fault diagnosis, repair and adjustment of system components. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T
4 3 1 4
General Goal: The course gives the trainees the understanding of different types of diesel fuel injection systems and components, as well as the construction and operation of system parts. In addition to hands on experience of faultfinding, inspection, repair, and adjustment of system components.
Behavioral Objectives: The trainees should be able to: Identify components of a diesel fuel injection system. Explain the construction and operation of injection system elements. Locate faults and adjust an injection system without disassembly. Adjust and calibrate different types of injection pumps on a test bench. Adjust and calibrate injectors. Repair injection pumps and injectors through replacement of defective parts.
- 70 -
Heavy Equipment
Topics
Diesel fuel injection systems Fuel supply pumps Fuel filters Diesel fuel injection pumps (high pressure pumps) Diesel fuel injectors Electronic diesel control (EDC) Fault diagnosing, repair, and adjustment of diesel fuel injection system components
References:
Diesel Engine and Fuel Systems, Barry Wellington and Alan Asmus Diesel and Mobile Plant Technology, Clifford M. Tempest
- 71 -
Heavy Equipment
2-Fuel supply pumps: Types of fuel supply pumps (pistondiaphragm-electric pumps) Construction and operation of supply pumps Faults in diesel fuel supply pumps Explain different types of diesel fuel supply pumps and operation Determine faults in supply pumps
3-Fuel filters: Types of fuel filters Filter element materials Fuel paths in filters Effect of fuel filters on faults in injection systems Explain types of fuel filters and operation and the effect of filter faults on diesel injection system performance.
- 72 -
Heavy Equipment
5-Diesel fuel injectors: Types of diesel fuel injectors Construction and operation of diesel fuel injectors Identify injector parts and operation. Test injectors on specialized testers.
6-Electronic diesel control (EDC): Electronic control system for inline and distributor pumps Electronic control system components (sensors-actuators-control unit) Identify the components of an electronic diesel control system. Explain the theory of operation of electronic diesel control systems.
- 73 -
Heavy Equipment
2-Adjustment, repair, and replacement of: Fuel filters Supply pumps Replace fuel filters. Repair fuel supply pump.
3-Testing of diesel fuel injection system on test bench: Simulation of fuel system faults and relating these faults to possible causes such as hard starting, loss of engine power, irregular engine running, engine knock...etc. Apparent inspection of piping, hoses, electrical connections, to determine leakage and faults. Injection timing Smoke testing Bleeding injection system Repair and replacement of supply lines (high pressure tubes-return pipes-filters) Identify diesel injection system faults and possible causes. Inspect fuel injection circuits. Bleed air from injection circuits.
10
- 74 -
Heavy Equipment
Behavioral Objectives The trainees should be able to: Inspect, repair, test, and adjust injectors.
Disassemble, cleaning repair and reassembly of injector Inspection and repair of injector Injector testing (leakage-injection pressure-dribble-atomization tests)
Use of high pressure pump test bench to determine: leaks-rack position-fuel spill off-fuel quantity at different rpm and positions of control rack Compare results with manufacturer data
Use of high pressure pump test bench to test: transfer pump-automatic advancemaximum fuel delivery-fuel cut offgovernor setting-injection timing Compare results with manufacturer data
- 75 -
Heavy Equipment
Inspection of EDC elements (sensorsactuators-controller) Replacement of the components of diesel injection electronic control systems
- 76 -
Heavy Equipment
In this course the identification of types of technical drawings (including the use of graphical charts) to indicate the relationship of different parameters in vehicle area, and the use of schematic drawings to indicate the components of different vehicle mechanical and electrical systems, their symbols and stages of operations will be covered. The course also includes the use of engineering drawing to draw vehicle components and elements, as well as the use of assembly drawing and sections of vehicle system parts.
4 2 4 -
General course objectives: This course aims at training the automotive technician trainees to conceive and follow up the illustrative diagrams of circuits and parts included in technical maintenance books. This helps the trainees to understand the relationships of different parameters affecting parts operation and performance, and acquisition of the necessary skills to use technical drawing as a means of illustration and conveyance of ideas.
- 77 -
Heavy Equipment
Detailed Objectives First: Procedural Objectives: The trainees should be able to:
Related Tasks
1) Draw schematic diagrams (vehicle system - Drawing of circuits circuits steps and stages of operation of (electrical electronic vehicle units). mechanical) 2) Draw engineering drawings for vehicle system elements. - Drawing of fittings and power transmission elements
- Assembly drawing for sectioned parts and units of vehicle system and locating dimensions on them
B5, B8, C5, D4, D7, D8, D10, G1, G10, G16, H1..H5, K4, L3, E9..E11, F4, G13, G14, I1..I4, I8, I9, I!2..I14, I16, J11, K10, K15, K16 E8, F5, G3, H1, H2, I1, J4
Second: Auxiliary Objectives (Cognitive and Behavioral): The trainees should be able to: 1) Understand the graphical charts. - Explanation of parts design and construction - Writing of technical reports A9
2) Understand diagrams in books and catalogues. 3) Express technical ideas using drawings.
C5
Safety Requirements: Clean place of work with good ventilation and lighting.
- 78 -
Heavy Equipment
Subjects (Theoretical and Practical) Graphical charts Schematic diagrams Assembly drawing Exploded drawing (individual for internal parts of components) Application of engineering drawing B9, C5
Related Tasks
- Understand technical drawings and become familiar with maintenance and repair books
Detailed Practical Course Hours Technical drawings: - Identification of the types of technical drawings Graphical drawing: 8 - The purpose of graphical drawing - Types of graphical drawings - Method of representation of graphical drawings - Applications on graphical drawings Content Evaluation Tools Direct observation Written questions
Schematic diagrams: 14 - The purpose of schematic diagrams - Types of schematic diagram - Symbols used in schematic diagrams - Applications on schematic diagrams
- 79 -
Heavy Equipment
Detailed Practical Course Hours Content Applications of engineering drawing: - Fasteners and their attachments (bolts rivets welding) - Power connection elements and attachments (shafts keys splines sliding bearings roller bearings seals) - Power transmission elements and attachments (sprockets gears cams springs) - Assembly drawing and sections of some vehicle systems Evaluation Tools
22
- 80 -
Heavy Equipment
1- GTZ, Technical Drawing for Automotive Engineering. 2- Ahed Ali Alkhateeb, Engineering Working Drawing, Dar AlKheraiji for Publication & Distribution , 2002, ISBN 9960-879-09-7
References:
- 81 -
Heavy Equipment
Major Code
Trimester Course Description: This course covers the maintenance procedures for hydraulic/ pneumatic components and systems. It explains maintenance requirements and how some factors (seals, filters, fluid pressure & temperature) can affect system performance and protection. Also, the course gives recommended maintenance procedures for two systems (hydraulic and pneumatic) in heavy equipments. The practical part of the course contains a set of tests and maintenance services for the previously taught systems. Credit Hours (Hour/week) L W
4 5 4 2 4
General Goal: To convey to the trainees the principles of different maintenance procedures, and the various factors affecting system conditions. In addition to the required training to perform maintenance services.
Behavioral Objectives: The trainees should be able to: Know the important factors to check for system protection and maintenance. Know the required maintenance procedures for hydraulic/pneumatic components and systems. Carry out maintenance for heavy-duty hydraulic and pneumatic systems using instruction manuals. Check the repaired components using a hydraulic test bench.
- 82 -
Heavy Equipment
Topics
Basic concepts of maintenance Maintenance classification Important factors affecting system protection and maintenance Maintenance of hydraulic systems used in heavy equipment Maintenance of pneumatic systems used in heavy equipment Check & test components using the test bench Complete maintenance forms
References:
Fluid Power ( Theory & Application) ,J., Sullivan Printice Hall International, Inc., Upper Saddle River, New York, U. S. A., 1998 Fluid Power wit Applications, A.., Esposito, Printice Hall, Columbus, Ohio, U. S. A., 1980 Diesel Equipment, Vol.I &Vol.II, E.,J., Schulz McGraw-Hill book Company, New York, U.S.A. 1982 Moving the Earth ( The Handbook of Excavation), H., L., Nichols, North Castle Books, Greenwich, Connecticut,
- 83 -
Heavy Equipment
10
2-Important factors to be considered for hydraulic and pneumatic system maintenance: Study the effects of: (lubricating oil, seals, filters, gaps between moving parts, gas and particle leakage to the system, temperature and pressure variations) 3-Recommended procedures to perform component maintenance for heavy-duty hydraulic systems: Determination of list of steps in sequence to service pump, valves, etc 4-Recommended procedure to perform component maintenance for heavy-duty pneumatic systems: Determination of list of steps in sequence to service compressor, valves, etc
Evaluate the component and system conditions based on a check of the relevant factors
- 84 -
Heavy Equipment
Check gas and solid particles leakage and carryout the required services (bleeding, cleaning, etc)
Check and test pressure and temperature in system components (pump, valves, etc) to find any faults and repair them
- 85 -
Heavy Equipment
2-Checks and tests to be periodically performed for maintenance of heavyduty pneumatic systems: Check of air leakage
Check and test pressure and temperature in the system components to find any faults and repair them.
- 86 -
Heavy Equipment
Major Code
Trimester Course Description: This course covers the different suspension and steering systems used in heavy equipment. It studies diverse types of wheels and tyres, suspension elements and systems for single and tandem axles, and various steering systems (conventional steering, hydrostatic steering, skid steering) In the practical part of the course, the trainees are trained how to inspect, test, disassemble and assemble the above-mentioned systems. Credit Hours (Hour/week) L W
5 5 3 4
General Goal: The course aims to give the trainees essential information about suspension and steering systems related to heavy equipment. Another goal of the course is to provide training to service the previously taught systems.
Behavioral Objectives: Learn fundamental concepts of suspension and steering. Have a working knowledge of different suspension and steering systems. Explain how steering angles affect tire wear and directional stability. Carry out different types of tests, disassembly and assembly operations.
- 87 -
Heavy Equipment
Topics
Basic concepts of suspension & steering Wheels, tires & bearings Suspension components Leaf spring suspension systems for single & tandem axles Air spring suspension systems Alignment angles Conventional steering systems Power steering systems Other steering systems (hydrostatic, articulated, etc) Four-wheel steering systems
References:
Diesel Equipment,Vol.I&Vol.II, E.,J., Schulz McGraw-Hill book Company, New york, U.S.A. 1982 Heavy Duty Truck Systems , I., Norman, R., Scharff , J., Corinchock, Delmar Phblishers, Albany,N.Y., U.S.A..1992 Medium/Heavy Duty Truck Steering &Suspension, D., Knowles, Albany, N.Y., U.S.A.. 1999 Moving the Earth ( The Handbook of Excavation), H., L., Nichols, North Castle Books, Greenwich, Connecticut,
- 88 -
Heavy Equipment
Basic concepts: The trainees should be able to: Identification and classification of heavy equipment, fluids and maintenance Classify heavy equipment and fluids and be aware of their main Fluid application for transporting force uses. and motion
Wheels and tyres: Study of different wheels, bearing and tyres (types, components, coding identification) Effect of inflation pressure and other factors
Identify different types of wheels and tires as well as their components and coding identification. Be aware of risks related to inflation pressure and other factors.
Suspension components: 4 Springs, shock absorbers (function, operation) Other supporting rods
Identify the various suspension components and how they work. Be familiar with their heavy-duty factures,
- 89 -
Heavy Equipment
Suspension systems
- Conventional suspension (with steel springs): Solid axle and independent suspensions Front suspensions types - with leaf springs and shock absorbers - with leaf springs and radius rods Rear suspensions-single axle -With leaf springs and shock-absorbers Rear suspension-tandem axles -With leaf springs and torque rods - With leaf springs and equalizing beams 4.2- Air spring suspension: Characteristics, components and operation
Differentiate between solid and independent suspensions Have a working knowledge of various types of front and rear suspensions. Understand the reasons for using air spring suspension systems as well as their components and operation.
- 90 -
Heavy Equipment
- Steering systems: Conventional steering system types Steering system components and operation Under steer and over steer effects
Be familiar with different conventional steering systems. Understand how they work.
Have a working knowledge of the features, operation and components of hydrostatic steering systems. Identify the particular features of articulated steering systems.
- 91 -
Heavy Equipment
- 92 -
Heavy Equipment
Behavioral Objectives The trainees should be able to: List the safety rules and apply them. Perform the necessary checks, disassembly, assembly and adjustment tasks. .
Application of safety rules relevant to wheel and tyre disassembly and assembly Inspection ,disassembly and assembly of wheels and tyres Inspection and adjustment of bearings in addition to substitution of defected ones
. 2-Conventional suspension: Front suspension (inspection of springs, shock absorbers, mounting brackets, bolts and rods in addition to the disassembly and assembly of components) Be familiar with the different front suspension systems. Mount and demount suspension systems components.
Rear single axle suspension (inspection, component mounting and demounting) Rear tandem axle suspension (inspection, component mounting and demounting)
Have a working knowledge of the different rear suspension systems. Be capable of performing all required component services.
3- Air spring suspension: Component inspection of air spring suspension systems Adjusting body height Mounting and demounting system components
To inspect, measure and adjust different components and variables. Remove and install procedures for air spring suspension.
- 93 -
Heavy Equipment
4- Wheel alignment: Complete the required inspection before performing wheel alignment Performing front-end alignment (camber, caster, toe) Performing rear wheel alignment (camber, toe)
6Hydraulic systems:
power-steering
Inspection of power-steering system components Test of power-steering pump and different valves Assembly and disassembly of system components as well as pre-load adjustment of steering gear
Inspect and test different elements. Mount, demount and adjust system components. .
- 94 -
Heavy Equipment
System component inspection (valves, power cylinder, etc) Remove and installation of defective components
Investigate different faults (leak, wear, etc) through appropriate checks and tests. Replace air-assisted suspension components.
10-Skid steer systems: 4 Inspecting system components and performing other service operations
11- Four-wheel steering systems: 4 Performing the required service operations (inspection, replacement, etc)
Understand the advantages of four-wheel steering systems. Perform different service operations.
- 95 -
Heavy Equipment
Mechanical Technology
Major Code
Heavy Equipment
HEQ263
Trimester Course Description: This course covers heavy equipment types; usage, inspection, maintenance, operational procedure and periodical maintenance. Also, this course covers the parameters affecting the life cycle of equipment. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T
4 5 4 2 4
General Goal: The course is designed to give the trainees a basic understanding of modern program systems used for heavy equipment, according to maintenance programs that meet manufacturers recommendations.
Behavioral Objectives: The trainees should be able to: Identify the different type of heavy equipment. Describe the main components of heavy equipment. Describe operation procedure. Perform control systems inspection and maintenance. Prepare tables of periodical maintenance.
- 96 -
Heavy Equipment
Topics
Heavy equipment types Wheeled equipment Tracked equipment Dumpers Scrapers Wheel loader Bulldozer Backhoe Compactors Fork lift Grader Wheeled tractors Three points pulling system Operation precautions Periodical maintenance tables
References:
- 97 -
Heavy Equipment
Dumpers: Dump trucks Bottom dumpers Articulated steering dumpers Tractor Scrapers: Operation and design Wheel dozers: Types of dozers edge Backhoes Compactors Wheeled loader: Operation and design Fork lift: Components operations Wheeled tractors: Three point pulling system Power take off
- 98 -
Heavy Equipment
Selecting suitable oil Oil circuit failures The benefits of maintenance programs Maintenance program structure Equipment safety regulations
Parameters affection life cycle: Structure parameters Production parameters Usage parameters The effect of running conditions on cycle life
Prepare equipment for work Equipment store. Steps for selecting new equipment
The principles of operations. The storing of equipment. The steps for selecting new equipment.
- 99 -
Heavy Equipment
10
10
Wear: Types of wear Reasons of wear Preventive maintenance for hydraulic circuits: Selecting oil Basic failures Maintenance program goals
- 100 -
Heavy Equipment
Maintenance tables: 50 hrs maintenance 250 hrs maintenance 500 hrs maintenance 1000 hrs maintenance 2000 hrs maintenance 3000 hrs maintenance
10
Prepare equipment for work Equipment store Steps for selecting new equipment
The principles of operations. The storing of equipment. The steps for selecting new equipment.
- 101 -
Heavy Equipment
Major Code
Heavy Equipment
HEQ253
Trimester Course Description: This course provides basic knowledge of heavy equipment control systems, and studies the performance of control systems. Examples of heavy equipment control systems are also provided. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T
4 5 4 2 4
General Goal: The course is designed to give the trainees basic knowledge of different control systems used in heavy equipment, operation maintenance and fault diagnostics.
Behavioral Objectives: The trainees should be able to: Identify the different type of hydraulic control systems. Be familiar with the open and closed control systems. Operate, adjust and maintain hydraulic control systems. Use fault diagnostics.
- 102 -
Heavy Equipment
Topics
Introduction to control systems Open control systems Closed control systems Basic components of heavy equipment control systems Examples of heavy equipment control systems Control system maintenance Fault diagnostics
References:
- 103 -
Heavy Equipment
Types of control systems: Open control systems Closed control systems Comparison between open and closed control systems
Hydraulic control systems components: Hydraulic pumps Hydraulic motor Hydraulic cylinder Control valves Servo valves
Fork-lift control system: Fork lift hydraulic control system component Lift position Lowering position Front tilt position Back tilt position Side movement
- 104 -
Heavy Equipment
Loader control system: Loader hydraulic control system components Lift position Lowering position Bucket filling and empty Ripper lift operation Ripper tilt operation
- 105 -
Heavy Equipment
12
Hydraulic control system components: Hydraulic pumps Hydraulic motor Hydraulic cylinder Control valves Servo valves
12
Adjust and maintain fork-lift control systems: Fork-lift hydraulic control system components Lift position Lowering position Front tilt position Back tilt position Side movement
12
Adjust and maintain dozer control systems: Dozer hydraulic control system components Natural position Blade lift operation Blade tilt operation Ripper lift operation Ripper tilt operation
- 106 -
Heavy Equipment
12
Adjust and maintain loader control systems: Loader hydraulic control system components Lift position Lowering position Bucket filling and empty Ripper lift operation Ripper tilt operation
- 107 -
Heavy Equipment
Major Code
HEQ173
Heavy Equipment
HEQ262
Trimester Course Description: This course focuses on heavy equipment traction systems, principles of operation for traction systems, design, various types, main components and system performance. Also covered are the basic knowledge of dynamic forces and resistance occurred during equipment operation. Credit Hours (Hour/week) L Contact Hours (Hour/week) W T
4 5 4 2 4
General Goal: The course is designed to give the trainees basic knowledge of different traction systems used in heavy equipment, operation maintenance and fault diagnostics.
Behavioral Objectives: The trainees should be able to: Identify the different type of traction systems. Determine coefficient of adhesion. Calculate equipment tractive effort. Calculate wheel reactions. Define traction system efficiency. Identify the parameters affecting traction effort.
- 108 -
Heavy Equipment
Topics Types of control systems Types of tyres Crawler track Parameters affecting equipment traction effort Rubber tracks Equation of motion Tractive effort Resistances Reactions Efficiency Slip Examples of heavy equipment control systems
References:
- 109 -
Heavy Equipment
Traction dynamics: Equations of motions Traction effort Resistances Reactions Efficiency Slip Parameters affecting traction effort.
Tyres: Type of tyres used on heavy equipment Tyre construction Tyre wear Tyre maintenance Traction aids
Different types of tyres used for heavy equipment. Contraction and parameter affecting tyre life. Traction aids.
Under-carriage: Under-carriage components Dismount and mount crawler track Crawler track maintenance Crawler track tension adjustment Track tension effect on traction effort Track specifications
Crawler track dismantling and installation. The effect of track tension on tractive effort.
- 110 -
Heavy Equipment
Rubber tracks: Dismount and mount of rubber track. Effect of track tension on traction effort Rubber track maintenance Track tension adjustment Track tension effect on traction effort Track specifications
The rubber track mount and dismount. The effect of track tension on traction effort.
- 111 -
Heavy Equipment
14
Tyres: Type of tyres used in heavy equipment Tyre construction Tyres inspection Mount and dismount of tyres Tyres wear Tyre maintenance Tyre balance Tyre size Traction aids
Different types of tyres used on heavy equipment. Contraction and parameter affecting tyre life. Tyre maintenance, balance and storing. Tyre dismantling and installation. Traction aids.
20
Under-carriage: Crawler track specifications Advantages of crawler track Mount and dismount crawler track Dismantle under-carriage Crawler track maintenance Dismantle and assemble idler and sprocket Dismantle and assemble track rollers Crawler track tension adjustment
Under-carriage components. Dismantling and installation. Adjust tract tension. Inspecting under-carriage components.
- 112 -
Heavy Equipment
10
Rubber tracks: Dismount and mount of rubber track. Effect of track tension on traction effort Rubber track maintenance Track tension adjustment Track tension effect on traction effort Rubber track storing Track specifications
Rubber track dismantling and installation. Maintenance. The effect of track tension on tractive effort.
- 113 -