Troubleshoot Auxiliary Power Unit (APU) 63H34C04 / Version MOSC 01 Oct 2004

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

091-63H30

MOSC

Tracked Vehicle Mechanic(BNCOC)

Task Number

Task Title

INDIVIDUAL 091-63H-3120 (*) 091-63H-3139 (*) Perform Diagnostics on Electrical Circuits on a Track Vehicle (M113/M88/M993/M48A5) Perform Diagnostics on the Auxiliary Power Unit (APU) on a M88A1 Track Recovery Vehicle
Task Title

Reinforced Task(s) Academic Hours

Task Number

091-109-0006

Maintain Equipment Inspection and Maintenance Worksheet (DA Form 2404) and (DA Form 5988-E)

The academic hours required to teach this lesson are as follows:

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

1 hr 7 hrs 0 hrs 0 hrs 8 hrs

Hours

/ Conference / Discussion / Practical Exercise (Performance)

Lesson No.

Testing
(to include test review)

2 hrs 6 hrs

25 mins 25 mins

63H34C07 version MOSC 63H34C08 version MOSC

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions

Lesson Number

Lesson Title

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the USA CASCOM, Training Directorate foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.

References

Number

Title

Date

Additional Information

TM 11-6625-3199-14

TM 9-2350-256-10 TM 9-2350-256-20

TM 9-2350-256-34-1

TM 9-4910-571-12&P

Operators, Unit, Intermediate Direct Support, and General Support Maintenance Manual for Digital Multimeter AN/PSM-45A (NSN 6625-01-265-6000) Operator's Manual for Recovery Vehicle, Full Tracked, Medium, M88A1 (NSN 2350-00-122-6826) Unit Maintenance Manual for Recovery Vehicle, Full Tracked, Medium, M88A1 (NSN 2350-00-1226826) (This Item is Included on EM 0036) Direct Support and General Support Maintenance Manual for Recovery Vehicle, Full Tracked, Medium, M88A1 (NSN 2350-00-122-6826) Operator's and Organizational Maintenance Manual Including Repair Parts and Special Tools List for Simplified Test Equipment for Internal Combustion Engines (Reprinted W/Basic Incl C1-2)(This Item is Included on EM 0068)

15 Dec 1988

31 Mar 1998 15 Jul 1996

28 Jan 1977

25 Mar 1988

Student Study Assignments Instructor Requirements Additional Support Personnel Requirements Equipment Required for Instruction

None for this lesson. One instructor per group.

Stu Ratio

Name

Qty

Man Hours

None
Id Name Stu Ratio Instr Ratio

Spt

Qty

Exp

2350-00-122-6826 RECOVERY VEHICLE, FULL TRACKED 4910-00-754-0654 SHOP EQUIPMENT, AUTOMOTIVE VEHICL 5120-00-624-8065 PLIERS, SLIP JOINT 5180-00-177-7033 TOOL KIT, GENERAL MECHANIC'S 6625-01-265-6000 MULTIMETER 70210N Computer; Mirco Laptop portable AC/DC W/Battery pack *P16312 Light PRO Projector *ZX7024 Industry Standard Laptop Computer * Before Id indicates a TADSS

1:4 1:16 1:4 1:4 1:4 1:1

No No No No No No

0 0 0 0 0 0

No No No No No No

1:16 1:16

No No

1 1

No No

Materials Required

Instructor Materials: 63H34C04 Slides Computer w/projector 63H34C04, PE 1, Solutions 63H34C04, PE 2, Solutions Electrical Schematics Student Materials: 63H34C04, Suppl. 1, Procedures 63H34C04, Suppl. 2, Procedures 63H34C06 Student handout 1 TM 9-2350-256-10, Mar 98 TM 9-2350-256-20, Jul 96 TM 9-4910-571-12&P, Mar 88 TM 11-6625-3199-14, Dec 88 Goggles, Industrial, (16) Pan, Drain, (4) Analyzer, Set Engine, STE/ICE-R, (4) Conduit Slip-Joint Pliers (Plastic Jaw), (4) Tool Kit, General Mechanic, (4) Multimeter, Digital, AN/PSM-45A, (4) Recovery Vehicle, Full Tracked, Med, M88A1, (4)

Classroom, Training Area, and Range Requirements Ammunition Requirements Instructional Guidance

General Instruction Building Vehicle Maintenance Instructional Building

Id

Name

Exp

Stu Ratio

Instr Ratio

Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

Proponent Lesson Plan Approvals

Name

Rank

Position

Date

gerard, gregory Deilus, John

GS 11 GS 12

Military Analyst Military Analyst

17 Sep 2004 20 Sep 2004

SECTION II.

INTRODUCTION

Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Small Group Instruction (SGI)
Motivator

The M88A1 medium recovery vehicles auxiliary power unit consists of an aircooled diesel engine with a chain case, generator, and hydraulic pump mounted to it. With a support and mounts, the engine, generator/starter, and pump form a compact unit, which fits into the right forward compartment. As a maintenance supervisor/repairer, it will be your job to keep it in top working condition.
NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action:

Terminal Learning Objective

Perform Diagnostics on the Auxiliary Power Unit (APU) on a M88A1 Track Recovery Vehicle In a classroom environment given required equipment, applicable tracked vehicle, general mechanic's tool kit; applicable special tools, TMDE, required safety equipment, and applicable forms and references.

Conditions:

Standards:

IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position.

Risk Assessment Level Environmental Considerations

Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.
NOTE: It is the responsibility of all soldiers and DA civilians to protect the environment from damage.

When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.
Evaluation

Describe how the student must demonstrate accomplishment of the TLO. In lesson 63H34C07, Job Knowledge Test, the student must achieve at least a 70% score and complete the test within one and half hours. In lesson 63H34C08, Job Performance Test, the student must achieve a GO and complete the test within one hour. We are now ready to begin our instruction on troubleshooting the auxiliary power unit.

Instructional Lead-In

SECTION III.

PRESENTATION

1.

Learning Step / Activity 1. Identify characteristics of the M88A1 APU. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference / Discussion 1:16 40 mins Small Group Instruction (SGI)

NOTE: NOTE:

Issue 63H34C06, Student Handout 1 to students and have them follow along with slide presentation. Show Slide 1. The APU consists of an overhead-valve, two-cylinder, four-cycle, air-cooled, diesel engine connected directly to a 300-A, 28-V, shunt-wound, dc generator (which is also used as a starter), and an auxiliary hydraulic system pump. The APU provides electrical power to charge the vehicle batteries, acts as a fuel transfer pump, provides hydraulic power for the impact wrench, emergency hydraulic power to raise and lower the spade, stow and raise the boom, and retrieve the main and hoist winch cables.

NOTE:

Show Slide 2. a. Location of the APU: The APU is located on the right/rear side of the hull.

NOTE:

Show Slide 3, APU front view: 1. 2. 3. 4. 5. 6. Engine combustion air inlet. Exhaust tube. Governor speed adjustment screw which is adjusted by spring tension. Crankcase oil gage rod. Auxiliary generator/starter. Flywheel guard.

NOTE:

Show Slide 4 c. Fuel system: The fuel system filters and delivers fuel to the engine cylinders at the correct time for ignition. The system consists of a primary fuel filter, secondary fuel filter, and injection nozzles.

NOTE:

Show Slide 5. 1. Primary and secondary fuel filters. Located on impact wrench compartment on M88A1.

NOTE:

Show Slide 6. 2. Emergency fuel shutoff.

NOTE:

Show Slide 7.

3.

Fuel Injection pump-This pump is a constant stroke, plunger-type pump. The camshaft drives the pump and it delivers an accurate amount of fuel under high pressure to the injection nozzles. Injection nozzles-The nozzles open at a pressure of about 1750 psi and delivers fuel in a fine spray to the pre-combustion chamber at a correct time for ignition. Fuel return-Excess fuel is returned to the fuel tank after each injection cycle attached to each injection nozzle. A bleed valve on the return line allows excess fuel to combine with flow-through fuel from the injection pump.

4.

5.

NOTE:

Show Slide 8. 6. Fuel transfer pump-The fuel transfer pump operates off of the engine camshaft. Fuel is pumped from the vehicle right side fuel tank through the primary and secondary fuel filters to the fuel injection pump. Preheater and Glow plug-Used during cold start procedures.

7. NOTE: NOTE:

Show Slide 9 and point out the components on the APU. Show Slide 10. 8. 9. Preheat Relay-controls power to the preheater. Fuel Shutoff-cuts fuel to the fuel injection pump for shutdown of the APU.

NOTE:

Show Slide 11. c. Lubrication System: Pressure lubrication is provided to all working parts of the engine. The lubrication system includes a gear-type oil pump assembly with oil intake cup, a bypass valve, an oil cooler and oil filter mounted on the oil filter adapter assembly. Oil lines and passages distribute oil to the working parts of the engine. A crankcase breather is used to aid oil consumption control. The standpipe breather, located under the rocker arm cover, vents crankcase fumes from the rocker arm cover to the cylinder head intake port.

NOTE:

Show Slide 12. 1. Oil Pump Assembly- the gear type oil pump is mounted on the gear case back plate and is driven by the crankshaft gear. The pump draws oil from the crankcase, through the screened oil intake tube, and to the oil filter. A standpipe breather vents crankcase fumes from the rocker arm cover. Oil Filter- The oil filter element is mounted on the oil filter adapter. Oil drawn from the crankcase by the oil pump is forced through the oil filter to the rocker arm cover, crankshaft and crankshaft bearings, and to the connecting rod bearings. Oil then flows through he connecting rod passages to the piston pin bushings. A crankcase breather is used to aid in oil consumption control. Show Slide 13.

2.

NOTE:

3. 4.

Oil Cooler- Mounted on the oil cooler plate and located above the flywheel. Hoses connect the oil cooler to the oil filter adapter. Bypass valve assembly-The oil bypass valve is located on the rear bearing plate and is used to control oil pressure. The valve is normally closed. When oil pressure reaches about 25 psi the valve opens, allowing excess oil to flow directly back to the crankcase. Oil pressure switch- the normally open contacts of the oil pressure switch close at 14 + 2 psi decreasing pressure. The contacts open at 14 + 2 psi increasing pressure. Normal oil pressure is 16 to 25 psi.

5.

NOTE:

Show Slide 14. 6. Components Locations(a) Oil pump assembly (b) Oil intake cup (c) Bypass valve (d) Oil Cooler (e) Oil Filter (f) Crankcase Breather (g) Standpipe Breather (h) Rocker Arm Cover

NOTE:

Show Slide 15. (i) Oil drain valve (j) Drain handle

NOTE:

Show Slide 16. d. Starter/Generator System: A 300-ampere, 28 + 7 volt gen. Functions as a starter motor. When the preheat switch is actuated, 24 vdc is applied to the generator field coil from the preheat relay. When the start switch is actuated 24 vdc is applied to the generator armature from the starting relay. This motorizes the generator. The generator is coupled to the eng. by a drive chain. When the engine starts, the current in the armature reverses direction, and the motorized generator resumes normal generator operation.

NOTE:

Show Slide 17. 1. Starter/Generator-located on the left side.

NOTE:

Shoe Slide 18. 2. Chain Assembly- used to drive the starter/generator and the hydraulic pump. Mounted at rear of APU.

NOTE:

Show Slide 19. 3. Starter Relay-mounted on the right side of the engine.

NOTE:

Show Slide 20. e. Hydraulic system: The auxiliary system of the vehicle has the following functions: 1. 2. 3. To supply power for control and emergency operation of the boom. To supply power for control and emergency operation of the spade and winches. To supply power for operation of refuel pump and impact wrench.

NOTE:

Show Slide 21. 1. Hydraulic pump-used as a supplement to the main hydraulic system. Mounted on right side of APU.

NOTE:

Show Slide 22. f. Governor system- the constant speed governor maintains engine speed at 2000 + 100 rpm during changes in power demands, by automatically varying the throttle position. The governor uses a ball and cup mechanism on the camshaft gear as the sensing device. A yoke resting on the cup connects to and arm and spring mechanism controlling the throttle lever. Any change in the engine speed is transmitted from the cup to the yoke and to the throttle. An adjusting screw is provided on the front of the unit to adjust the speed by changing spring tension. To adjust the engine speed a hand held stroboscope must be used. (TM 9-2350-256-34-1 Pg. 4-20.3)

NOTE:

Show Slide 23. 1. Components of the Governor system(a) Speed adjustment nut (b) Injection pump (c) Control lever (d) Governor linkage and governor arm (e) Governor shaft (f) Governor yoke (g) Cam gear (h) Cup (i) Fly balls (j) Sensitivity adjustment nut

NOTE:

Show Slide 24. g. Power train assembly: internal components of the APU engine. 1. Components of the power train(a) Crankshaft (b) Connecting rod (c) Piston (d) Pushrod (e) Rocker arm (f) Valve (g) Shield (h) Tappet (i) Camshaft (j) Camshaft gear (k) Crankshaft gear (l) Oil pump drive gear

NOTE:

Show Slide 25. g. Fuel transfers system: used to transfer fuel from one vehicle to another, and to defuel the vehicle. 1. Components of the fuel transfer system(a) Control valve. (b) Regulating valve. (c) Fuel hose connections.

NOTE:

Show Slide 26. (d) Fuel transfer pump. (e) Refuel motor.

NOTE:

Show Slide 27. h. APU control box: located in the drivers compartment to the right/rear of the driver.

10

1.

Control box switches and indicators(a) APU generator switch-Must be off to start the APU. (b) Fuel switch. (c) Low oil pressure switch. (d) Preheat switch. (e) Starter switch- Current flow reverses when preheat and starter switches are released. (f) High air temperature light. (g) APU engine oil pressure.

NOTE:

Show Slide 28, Lead a discussion on the schematics and trace power into and out of the Auxiliary Power Unit (APU). Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Troubleshoot the Starting system. Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:4 3 hrs 25 mins Small Group Instruction (SGI)

NOTE: 2.

NOTE:

Conduct the practical exercise IAW 63H34C04, PE 1. Divide class into groups for the Practical Exercise. Issue to the group 63H34C04, PE 1 Practical Exercise Procedures. Move the groups to the shop floor. Restate safety requirements.

3.

Learning Step / Activity 3. Troubleshoot the charging system Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:4 3 hrs 25 mins Small Group Instruction (SGI)

NOTE:

Conduct the practical exercise IAW 63H34C04, PE 2. Divide class into groups for the Practical Exercise. Issue to the group 63H34C04, PE 2 Practical Exercise Procedures. Move the groups to the shop floor.

11

Restate safety requirements. NOTE: Conduct a check on learning and summarize the learning activity.

12

SECTION IV.

SUMMARY Method of Instruction: Conference / Discussion Instructor to Student Ratio is: 1:16 Time of Instruction: 5 mins Media: Small Group Instruction (SGI)

Check on Learning

Determine if the students have learned the material presented by soliciting student questions and explanations. Ask the students questions and correct misunderstandings. Q. Besides serving as a starter, what other job is performed by this component? A. Acts as a generator. Q. How is the hydraulic pump driven on the APU? A. By a chain that is driven by the cam gear.

Review / Summarize Lesson

13

SECTION V. Testing Requirements

STUDENT EVALUATION
NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

14

PRACTICAL EXERCISE SHEET 63H34C04 SUPPL. 1

Title Lesson Number / Title Motivator

Troubleshoot Auxiliary Power Unit (APU) starting sytem. 63H34C04 version MOSC / Troubleshoot Auxiliary Power Unit (APU) The M88A1 medium recovery vehicles auxiliary power unit consists of an aircooled diesel engine with a chain case, generator, and hydraulic pump mounted to it. With a support and mounts, the engine, generator/starter, and pump form a compact unit, which fits into the right forward compartment. As a maintenance supervisor/repairer, it will be your job to keep it in top working condition.
NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: Perform Diagnostics on the Auxiliary Power Unit (APU) on a M88A1 Conditions:

Terminal Learning Objective

Track Recovery Vehicle In a classroom environment given required equipment, applicable tracked vehicle, general mechanic's tool kit; applicable special tools, TMDE, required safety equipment, and applicable forms and references. IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Standards:

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position. Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.

Risk Assessment

63H34H04 Suppl 1

Environmental Considerations

When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.

Evaluation Instructional Lead-In Resource Requirements Instructor Materials:

63H34C04 Slides Computer w/projector 63H34C04, PE 1, Solutions 63H34C04, PE 2, Solutions Electrical Schematics

Student Materials:

63H34C04, Suppl. 1, Procedures 63H34C04, Suppl. 1, Procedures 63H34C06 Student handout 1 TM 9-2350-256-10, Mar 98 TM 9-2350-256-20, Jul 96 TM 9-4910-571-12&P, Mar 88 TM 11-6625-3199-14, Dec 88 Goggles, Industrial, (16) Pan, Drain, (4) Analyzer, Set Engine, STE/ICE-R, (4) Conduit Slip-Joint Pliers (Plastic Jaw), (4) Tool Kit, General Mechanic, (4) Multimeter, Digital, AN/PSM-45A, (4) Recovery Vehicle, Full Tracked, Med, M88A1, (4)
Special Instructions Procedures

a. Locate procedures in the Technical Manual to perform task for the fault found on 63H34C06, Suppl 1, DA Form 2404 troubleshoot the starting system. b. NOTE: Locate fault in technical manual.

Stop, make sure all caution and warning statements are read and closely followed to ensure no damage to personnel or equipment. c. Make sure all equipment conditions have been done before performing task.

63H34H04 Suppl 1

NOTE: WARNING:

Stop, have instructor check your work to make sure that the proper task is being performed. Attention: Ensure that hearing protection is worn whenever starting the vehicle or the APU. Also make sure that the master power switch is in the OFF position before connecting/disconnecting any electrical connections to prevent damage to equipment and possible harm to individuals. d. Perform the task of troubleshooting the starting system.

e. Ensure that keyways are in line before connecting any electrical connections to prevent damage to the connectors. f. NOTE: Perform the task until a solution is found.

Stop, Inform instructor at this time to verify solution. g. h. i. j. Fill out DA Form 2404 and turn it into the instructor. Perform all of the follow on procedures. Follow all safety precautions and warnings. Inform instructor when you are done, for further instructions, and wait

Feedback Requirements

63H34H04 Suppl 1

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34C04 SUPPL. 1 a. Verify students have located the Quick Guide to Troubleshooting TM9-2350-256-20 (M88A1), para 2-16 and identified fault annotated on 63H34C04 Suppl 1, DA Form 2404 (APU starter fails to crank). Make sure students read and understand all caution and warnings. b. CAUTION: Divide students into groups and direct them to their workstations.

Before the APU is operated make sure all personnel are wearing hearing protection, and that the area is well vented. c. Make sure all students understand the rules of the shop, especially to notify instructor whenever starting the vehicle or the APU.

NOTE:

Make sure all equipment conditions are met before students troubleshooting the electrical system. d. Have students perform the troubleshooting found in TM 9-2350-256-20.

NOTE: WARNING:

Make sure that students use the schematics along with the TM to follow the components that are being connected or disconnected and points that are being checked. Make sure that students insure that master power is off whenever connecting or disconnecting electrical lines. e. f. Inform students to notify instructor whenever a fault is found. After completion of the steps for troubleshooting the starting system,

g. Inform groups to annotate corrective action and turn in the DA Form 2404 to the instructor. NOTE: The solution for the fault is Step K; the 15-Amp circuit breaker is unserviceable. h. Verify students have located the Quick Guide to Troubleshooting TM 9-2350-56-20, (M88A1), page 2-37 and identified page 2-147 for the fault annotated on 63H34C06 Suppl 4 (Generator indicator reads in yellow or lower red region with APU engine running and APU generator switch on). Make sure students read and understand all caution and warnings. i. j. NOTE: Divide students into groups and direct them to their workstations. Make sure all students understand the rules of the shop, especially to notify instructor whenever starting or shutting down the vehicle or the APU

Make sure all equipment conditions are met before students troubleshoot the charging system. k. Have students perform the equipment condition referenced in the task found in TM 92350-277-20-1, page 008400-1.

63H34H04 Suppl 1

NOTE: NOTE:

Make sure that students use the schematics along with the TM to follow the components that are being connected or disconnected and points that are being checked. Make sure that students insure that master power is off whenever connecting or disconnecting electrical lines. l. Inform students to notify instructor whenever a fault is found.

NOTE:

Before the APU is operated make sure all personnel are wearing hearing protection. m. After completion of the steps for troubleshooting the charging circuit, make sure that all follow-on steps have been done. n. Inform groups to annotate corrective action and turn in Suppl 3 to the instructor.

NOTE:

The solution for the Fault is Step J, page 2-151; wire 62 is broken at bulkhead to APU, master relay & riggers lights wiring harness. o. p. Check work area for cleanliness, vehicle for serviceability and that all Direct students to next lesson.

63H34H04 Suppl 1

PRACTICAL EXERCISE SHEET 63H34C04 SUPPL. 2

Title Lesson Number / Title Motivator

Troubleshoot Auxiliary Power Unit (APU) charging system. 63H34C04 version MOSC / Troubleshoot Auxiliary Power Unit (APU) The M88A1 medium recovery vehicles auxiliary power unit consists of an aircooled diesel engine with a chain case, generator, and hydraulic pump mounted to it. With a support and mounts, the engine, generator/starter, and pump form a compact unit, which fits into the right forward compartment. As a maintenance supervisor/repairer, it will be your job to keep it in top working condition.
NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: Perform Diagnostics on the Auxiliary Power Unit (APU) on a M88A1 Conditions:

Terminal Learning Objective

Track Recovery Vehicle In a classroom environment given required equipment, applicable tracked vehicle, general mechanic's tool kit; applicable special tools, TMDE, required safety equipment, and applicable forms and references. IAW applicable technical publications, procedures, and specifications. When this task is complete, the vehicle must be fully mission capable. 1. Complete the solution sheet as the group performs the task. Once the group has correctly performed a step, place a check in the column. 2. Ensure that each student participates. Rotate students so that all members of the group use references, tools, and perform the hands on steps of the task. If time permits, repeat the task with different members performing different steps. 3. Ensure that the group completes each performance step IAW applicable references. 4. If a safety violation occurs, stop the group, correct on the spot and restart the group. 5. If a student misses the practical exercise or a team needs training for longer than the PE allows, then conduct this training IAW TRADOC regulations. 6. Check all work, have students clean work area, and store equipment.

Standards:

Safety Requirements

Hearing protection will be used when equipment is in operation. Safety goggles, should be worn while working under a vehicle. Hard hats will be worn when using an overhead lifting device. Remove all jewelry and I.D. tags before any work is started. Use safety stands while vehicle is in the raised position. Low - It is the instructor's responsibility to conduct a risk assessment prior to instruction using FM 100-14 as guidance. A copy of the risk management work sheet must be present at time of instruction.

Risk Assessment

63H34H04 Suppl 2

Environmental Considerations

When working with equipment, in the event of an accidental spill of hydraulic fluid, fuels, oils, solvents, acids, and coolants, the spill must be contained and cleaned up immediately. Floor dry sweep is the most effective material to contain and clean up environmental spills. The student will report the incident to the instructor immediately. The instructor will direct appropriate cleanup actions. All contaminated floor dry materials must be stored in a separate container. The container must be inspected by qualified environmental specialists to determine proper disposal procedures. Additional warnings and cautions concerning environmental hazards will be explained to you at the applicable point in later lessons.
Instructor Materials:

Resource Requirements

63H34C04 Slides Computer w/projector 63H34C04, PE 1, Practical Exercise solutions 63H34C04, PE 2, Practical Exercise solutions Electrical Schematics
Student Materials:

63H34C04, Suppl. 1, Procedures 63H34C04, Suppl. 2, Procedures 63H34C06 Student handout 1 TM 9-2350-256-10, Mar 98 TM 9-2350-256-20, Jul 96 TM 9-4910-571-12&P, Mar 88 TM 11-6625-3199-14, Dec 88 Goggles, Industrial, (16) Pan, Drain, (4) Analyzer, Set Engine, STE/ICE-R, (4) Conduit Slip-Joint Pliers (Plastic Jaw), (4) Tool Kit, General Mechanic, (4) Multimeter, Digital, AN/PSM-45A, (4) Recovery Vehicle, Full Tracked, Med, M88A1, (4)
Special Instructions Procedures

a. Locate procedures in the Technical Manual to perform task for the fault found on 63H34C06, Suppl 2, DA Form 2404 troubleshoot the charging system. b. NOTE: Locate fault in technical manual.

Stop, make sure all caution and warning statements are read and closely followed to ensure no damage to personnel or equipment. c. Make sure all equipment conditions have been done before performing task.

NOTE:

Stop, have instructor check your work to make sure that the proper task is being performed.

63H34H04 Suppl 2

WARNING:

Attention: Ensure that hearing protection is worn whenever starting the vehicle or the APU. Also make sure that the master power switch is in the OFF position before connecting/disconnecting any electrical connections to prevent damage to equipment and possible harm to individuals. d. Perform the task of troubleshooting the charging system.

e. Ensure that keyways are in line before connecting any electrical connections to prevent damage to the connectors. f. NOTE: Perform the task until a solution is found.

Stop, inform instructor at this time to verify solution. g. h. i. j. k. l. Fill out DA Form 2404 and turn it into the instructor. Perform all of the follow on procedures. Follow all safety precautions and warnings. After completing the task, clean up around work area. Turn in all tools and equipment and clean work area. Inform instructor when you are done, for further instructions, and wait

m. Wait to be directed to your next class.

Feedback Requirements

63H34H04 Suppl 2

SOLUTION FOR PRACTICAL EXERCISE SHEET 63H34C04 SUPPL. 2 a. Verify students have located the Quick Guide to Troubleshooting TM 9-2350-25620, (M88A1), para 2-16 and identified the fault annotated on 63H34C04 Suppl 2 (Generator indicator reads in yellow or lower red region with APU engine running and APU generator switch on). Make sure students read and understand all caution and warnings. Divide students into groups and direct them to their workstations. Make sure all students understand the rules of the shop, especially to notify instructor whenever starting or shutting down the vehicle or the APU

b. c. CAUTION: WARNING:

Make sure that students insure that master power is off whenever connecting or disconnecting electrical lines. Before the APU is operated make sure all personnel are wearing hearing protection. Make sure all equipment conditions are met before students troubleshoot the charging system. d. Have students perform the equipment condition referenced in the task found in TM 9-2350-256-20.

NOTE:

NOTE: NOTE:

Make sure that students use the schematics along with the TM to follow the components that are being connected or disconnected and points that are being checked. Make sure that students insure that master power is off whenever connecting or disconnecting electrical lines. e. f. g. Inform students to notify instructor whenever a fault is found. After completion of the steps for troubleshooting the charging circuit, make sure that all follow-on steps have been done. Inform groups to annotate corrective action and turn in the DA Form 2404 to the instructor.

NOTE:

The solution for the Fault is Step J, wire 62 is broken at bulkhead to APU, master relay & riggers lights wiring harness. h. i. Check work area for cleanliness, vehicle for serviceability and that all tools and equipment have been put away. Direct students to next lesson.

63H34H04 Suppl 2