2005 US Army Student Guide 69p

62B10 (R) ADT, PHASE 2 CONSTRUCTION EQUIPMENT REPAIRER STUDENT GUIDE
SHOP OPERATIONS
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.
Student Materials: Student Guide Pens and Pencils
Procedures: Station One: At this station you have a piece of round stock and a piece of bar stock. Using TM 9-243 and guidance from 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 9243 and guidance from the instructor, you must: 1. Properly position the metal in the vice. NOTE: The instructor will tell you which size to use for item # 2 & 3. 2. Select the proper tap and die. 3. Properly use the tap to cut internal threads in the piece of flat stock. 4. Properly use the die to thread the round stock. 5. Insure that the threaded round stock fits the square stock you threaded.
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6. Clean and return the tap and die to their proper locations.
Station Three: At this station you have a piece of copper tubing, a tube cutter, and a flaring tool kit. Using TM 9-243 and guidance 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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ELECTRICAL SYSTEMS
PRACTICAL EXERCISE SHEET 62B10B01PE 1
Title Lesson Number / Title Resource Requirements Student Materials:
Identify Wiring Schematics 62B10B01 version ADT / Electrical Systems
* * * * * * * * * * * * * * * * *
TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-2420-224-24P TM 5-3805-261-20 TM 5-3805-261-24P TM 5-3805-262-20 TM 5-3805-262-24P TM 5-2410-237-10 TM 5-2410-237-20 TM 9-4910-571-12&P TM 9-6140-200-14 TM 11-6625-3199-14 TM 5-3805-262-20 wiring schematics Student guides Multicolor marking pens Pens and pencils
Procedures: Identify Wiring Schematics: Problem #1: 1) 2) 3) 4) 5) 6) 7) 8) 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.
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9)
Locate the defroster motor in the upper cab.
10) Locate the air pressure gage at the left instrument panel.
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Problem #2:
Using a red pen, trace a circuit to determine how power gets to the ignition key switch 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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Title
Identify the purpose of a battery, battery components, maintenance, safety, and environmental procedures. 62B10B01 version ADT / Electrical Systems
Lesson Number / Title
Student Materials:
* * * * * * * * * * * * * * * * * * * *
TM 5-2420-224-10 TM 5-2420-224-20-1 TM 5-2420-224-20-2 TM 5-2420-224-24P TM 5-3805-261-20 TM 5-3805-261-24P TM 5-3805-262-20 TM 5-3805-262-24P TM 5-2410-237-10 TM 5-2410-237-20 TM 9-4910-571-12&P TM 9-6140-200-14 TM 11-6625-3199-14 TM 5-3805-262-20 wiring schematics Student guides Multicolor marking pens Pens and pencils Rubber Apron Rubber Gloves Safety Goggles
Procedures
Problem #1
Perform a specific gravity test on a battery IAW TM 9-6140-200-14. Annotate the results on the 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
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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Title Lesson Number / Title Resource Requirements Student Materials:
Identify TMDE used for electrical system testing. 62B10B01 version ADT / Electrical Systems
* * * * * * * * * * * * * * * * *
Procedures:
Group one: Utilizing the appropriate TM the primary instructor will go through step-by-step procedures for the following: 1. Power up the SPORT or MSD in TK mode. 2. Perform battery voltage test. 3. Perform voltage output test, 0 to 45 volts DC. 4. Perform current output test, 0 to 1500 amps DC. 5. Power down the SPORT or MSD.
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Group two: Utilize a multimeter along with the knowledge you have gained in the previous electrical classes to perform the 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.
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Title Lesson Number / Title Resource Requirements
Troubleshoot a starting and charging system. 62B10B01 version ADT / Electrical Systems
Student Materials:
* * * * * * * * * * * * * * * * *
Procedures:
Site #1: Troubleshoot a starting system utilizing a digital multimeter:
a) b) c)
Locate components on MW24C wiring schematic Locate components on the MW24C Set multimeter up for the following measurements: (1) (2) (3) (4) Amperage DC Resistance Continuity Voltage DC
d) e)
Utilize a digital multimeter to perform a battery voltage test troubleshoot Locate Starter Does Not Crank deficiency in the TM troubleshooting chart.
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f) Follow sequence outlined in the troubleshooting chart. instructor of the fault when identified.
g)
Inform
Site #2: Troubleshoot a starting and charging system utilizing a MSD / SPORT
You will utilize a SPORT / MSD to diagnose the following situations: a) On the D7G Dozer in DCA mode run the complete GO chain and the following test from the NO 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 You will utilize a digital multimeter to troubleshoot the following faults: a) On the MW24C Scoop Loader, utilize a digital multimeter to troubleshoot the following deficiency: 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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Replace a switch, replace batteries, and repair a wiring harness. 62B10B01 version ADT / Electrical Systems
Student Materials:
TM 5-3805-261-20 TM 5-3805-262-20
Procedures:
Station # 1: At this station you (the student) have a MW24C Scooploader with the fault "Bucket does not return to digging position". Using the TM provided, follow the instructor's guidance and the troubleshooting procedures to determine the fault 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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DIESEL ENGINE SYSTEMS

PRACTICAL EXERCISE SHEET 62B10C01 PE1
Disassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems
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.
Procedures:
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.
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NOTE:
Starter weighs 65 pounds. f. Remove starter from engine and wrap in white mat and place on top of workbench. Have students retain starter mounting bolts and gasket for installation of 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.
d. Wrap coupling in rag and place in can marked TURBO.
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e. Cover/tie off openings of exhaust pipe and place on shelf. f. Reinstall nuts and bolts on exhaust manifold and place large plastic cap over 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. j. k. 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.
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. 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.
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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. 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.
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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:
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. 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.
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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:
Use dry sweep to clean up any fuel spilled at this point. d. Cover entire fuel pump with large rag. Reinstall timing gear cover on engine 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
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1) Removal of Rocker Arm Assembly a. Remove rocker arm cover and place upside down directly in front of radiator. b. Make six (6), one (1) ft square rags and remove any loose hanging threads and 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. 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.
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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. NOTE: Cylinder head weighs 142 lbs. Do 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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Reassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems
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.
Procedures:
1. REASSEMBLY OF ENGINE A. INSTALLATION OF CYLINDER HEAD AND SPACER PLATE 1) Installation of Cylinder Head Spacer Plate a. Thoroughly clean the spacer plate gasket, spacer plate, and cylinder block with 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: If head bolts are NOT torqued in sequence, possible engine damage could occur. 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 c. lb ft.
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. 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
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.
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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: 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. 2) Install the Fuel Injection Pump and Governor Assembly NOTE: Ensure the engine is at top center (TC) compression position for NO. 1 piston. a. Remove timing gear cover and rags covering holes. b. Put clean engine oil on the O-ring seals (two on bottom and two on front). c. Ensure the O-rings stay in place and position the fuel injection pump on the engine. Making sure the fuel injection pump camshaft slides into the hole in the fuel 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: 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.
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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 OVER-TIGHTEN 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. 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.
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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 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.
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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. 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.
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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.
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.
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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. 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, frays and wear that could cause leaks. Tighten or replace all lines and hoses that leak.
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4) Intake System: Check for the proper operation and condition of the intake system. Ensure 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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Title
Implement diagnostic test and adjustment procedures on diesel engines and components. 62B10C01 version ADT / Diesel Engine Systems
Lesson Number / Title
Student Materials:
Student Study Guide Equipment manuals extracts Practical exercise sheets Eye Protection Hearing Protection Coveralls
Procedures:
Station #1 At this station, you have a two-stroke or four-stroke diesel engine, TMDE, and the applicable TMs and references. 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. 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. 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. 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. Station #5
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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. 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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HYDRAULIC SYSTEMS
PRACTICAL EXERCISE SHEET 62B10D01PE1
Repair and replace a hydraulic cylinder. 62B10D01 version ADT / Hydraulic Systems
Student Materials:
Eye Protection Safety Boots Coveralls TM 5-2350-262-34 TM 5-3805-262-20
Procedures:
Problem One: Replace a hydraulic cylinder. At this station you are in an Organizational Maintenance environment. You have a MW24C Scoop Loader. 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.
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.
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Installation 1. Position clam cylinder assembly on rear of bucket. 2. Align cylinder tube yoke hole at bottom of cylinder with pivot hole in bucket. 3. Start pin into pivot hole at bottom of cylinder; be sure hole in pin is aligned with hole in cylinder. 4. Remove plugs and reconnect lines to cylinder assembly ports. 5. Using hammer and a brass drift drive pin into place at the bottom of the cylinder. 6. Install and tighten cap screw and lock nut at the bottom of the cylinder.
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Problem Two: Repair a hydraulic cylinder. At this station you have a hydraulic cylinder from an item of construction equipment that was removed by 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
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NOTE: Normally the setscrew would be replaced with a new one but for training purpose the same one is used. 8. 9. Secure cylinder head into cylinder with setscrew. Install two caps into oil ports.
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Title Lesson Number / Title Resource Requirements Instructor Materials:
Interpret hydraulic schematics.
62B10D01 version ADT / Hydraulic System
Vickers Hydraulics Manual
Student Materials:
Color markers Hydraulic simulator boards Student guides Vickers Industrial Hydraulics Manual inserts Pens and pencils
Procedures:
Problem #1: Retract circuit.
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RETRACT
#5
#9
500 PSI #11 #12
#10
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Problem #2: Retract at controlled speed circuit.
RETRACT AT CONTROLLED SPEED

#5
#12
#3
#9
500 PSI #11 #12
#10
Problem #3: Sequencing circuit extending.
SEQUENCING CIRCUIT
#5
300 PSI
#6
#2
#9
500 PSI #11 #12 #10
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Problem #4: Pressure reducing circuit extending.
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.
ROTARY DRIVE WITH SPEED CONTROL
#8
#9
500 PSI #11 #12 #3 #10
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Quiz.
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. CYLINDER NUMBER TWO 2. CYLINDER NUMBER FIVE 3. BOTH CYLINDERS AT THE SAME TIME
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4. NEITHER CYLINDER WILL EXTEND 9. WHAT COMPONENT IS ITEM NUMBER TEN? 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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Title
Charge an Accumulator.
Student Materials:
Actuator Accumulators Charging Device with nitrogen TMDE General mechanics tool kit Special tools Eye Protection Coveralls Student guide
Procedures
1. Follow the steps in the TM. 2. Insure all safety procedures are followed and eye protection and coveralls are worn. a. Disregard the highlighted areas. Instructor will explain. b. Instructor will provide students with the temperature. c. Instructor will assist students as needed.

Replace, Test, and Adjust Hydraulic Control Valves and Pumps. 62B10D01 version ADT / Hydraulic Systems
Procedures
1. Problem #1: Backhoe/crane pressure relief valve cannot be adjusted on the FLU 419 (SEE) At this station you are in a Direct Support Maintenance environment. You have 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 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.
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POWER TRAIN SYSTEMS

PRACTICAL EXERCISE SHEET 62B10E01 PE1
Perform Power Shift Transmission Troubleshooting, Repair, and Adjustments 62B10E01 version ADT / Power Train Systems
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
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.
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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Identify differential and axle components and their functions. 62B10E01 version ADT / Power Train Systems
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. 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. 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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Identify final drive components and their functions. 62B10E01 version ADT / Power Train Systems
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 Student guides Pens and pencils Eye & Hearing Protection Safety Boots Coveralls Work Gloves
Procedures
Station #1: At this station you have a 621B Scraper. Using TM 5-3805-248-14&P2 and following the instructors guidance, you will remove, disassemble, inspect, reassemble and replace the final drive assembly. Station #2a: At this station you have a D7G tractor, Full Tracked. Using TM 5-3805-237-20 and following 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. 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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BRAKE SYSTEMS
PRACTICAL EXERCISE SHEET 62B10F01PE1
Title Lesson Number / Title Resource Requirements
Correct an Air Brake System Malfunction. 62B10F01 version ADT / Brake Systems
Student Materials:
TM 5-3805-248-14&P1 TM 5-3805-248-14&P2 TM 5-3805-248-14&P3 TM 5-3805-248-14&P4 TM 5-3805-262-20 TM 5-3805-262-34 TM 5-3805-261-34 TM 9-2320-211-20 w/ch 1-3 TM 9-2320-211-20-1 w/ch 1 TM 9-2320-211-20-2-1 w/ ch 1 TM 9-2320-211-20-2-2 TM 9-2320-211-20-3 w/ch 1 TM 9-2320-211-20-3-2 TM 9-8000 Student guides Petroleum oil and lubricants Necessary maintenance forms Pens and pencils PPE
Practical Exercise #1, Problem #1: At this station you are in an Organizational Maintenance environment. You have an item of 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. 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. 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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Title Lesson Number / Title Resource Requirements Student Materials: Instructor Materials:
Correct a Hydraulic Brake System Malfunction. 62B10F01 version ADT / Brake Systems
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
TM 5-3805-248-14&P1
Procedures:
Practical Exercise #2, Problem #1: 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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Correct Assisted Brake System Malfunctions. 62B10F01 version ADT / Brake Systems
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 Eye Protection Coveralls Rubber gloves Work gloves
TM 5-3805-248-14&P1
Hearing Protection
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 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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PMCS
PRACTICAL EXERCISE SHEET 62B10G01PE1
Components of the BDAR Maintainer Kit
62B10G01 version ADT / Preventive Maintenance C
DA PAM 738-750 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
Procedures;
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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 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. 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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PRACTICAL EXERCISE SHEET 62B10G01PE2

Preventive Maintenance Checks and Services (PMCS) 62B10G01 version ADT / Preventive Maintenance Checks and Services (PMCS)
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 Student guides Pens and pencils Eye Protection Hearing Protection Safety Boots Coveralls Rubber Apron Rubber Gloves
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Procedures:
Station #1: 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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62B10 (R) ADT, PHASE 2 CONSTRUCTION EQUIPMENT REPAIRER STUDENT GUIDE

Student Materials: Student Guide Pens and Pencils

Identify Wiring Schematics 62B10B01 version ADT / Electrical Systems

Locate the defroster motor in the upper cab.

PRACTICAL EXERCISE SHEET 62B10B01PE 2

Lesson Number / Title

PRACTICAL EXERCISE SHEET 62B10B01PE 3

PRACTICAL EXERCISE SHEET 62B10B01PE 4

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

PRACTICAL EXERCISE SHEET 62B10B01PE 5

DIESEL ENGINE SYSTEMS

Disassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems

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

PRACTICAL EXERCISE SHEET 62B10C01 PE2

Reassemble a diesel engine. 62B10C01 version ADT / Diesel Engine Systems

PRACTICAL EXERCISE SHEET 62B10C01 PE3

Lesson Number / Title

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

PRACTICAL EXERCISE SHEET 62B10D01PE2

Interpret hydraulic schematics.

62B10D01 version ADT / Hydraulic System

Vickers Hydraulics Manual

Problem #1: Retract circuit.

500 PSI #11 #12

Problem #2: Retract at controlled speed circuit.

RETRACT AT CONTROLLED SPEED

500 PSI #11 #12

Problem #3: Sequencing circuit extending.

Problem #4: Pressure reducing circuit extending.

PRESSURE REDUCING CIRCUIT

Problem #5: Rotary drive with speed control.

ROTARY DRIVE WITH SPEED CONTROL

NAME____________________________________ Students # __________

10. WHAT TYPE OF RESERVOIR IS SHOWN? 1. 2. 3. 4. PRESSURIZED OPEN VENTED CLOSED

PRACTICAL EXERCISE SHEET 62B10D01PE3

PRACTICAL EXERCISE SHEET 62B10D01PE4

POWER TRAIN SYSTEMS

PRACTICAL EXERCISE SHEET 62B10E01 PE2

PRACTICAL EXERCISE SHEET 62B10E01 PE3

PRACTICAL EXERCISE SHEET 62B10F01PE2

PRACTICAL EXERCISE SHEET 62B10F01PE3

Components of the BDAR Maintainer Kit

62B10G01 version ADT / Preventive Maintenance C

PRACTICAL EXERCISE SHEET 62B10G01PE2

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NAME__________________________ Students #