2005 us army construction equipment repairer instructor's guide 193p

7/27/2019 2005 Us Army Construction Equipment Repairer Instructor's Guide 193p

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62B10 (R) ADT, PHASE 2

CONSTRUCTION EQUIPMENT REPAIRER

INSTRUCTOR'S GUIDE


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SHOP OPERATIONS

PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 2: 62B10A02 version ADT

PRACTICAL EXERCISE SHEET 62B10A07PE1

Title Proper Use of Tools.

Lesson Number / Title 62B10A02 version ADT / Employ Test, Measurementand Diagnostic Equipment (TMDE), generalmechanics and special tools.

Introduction

Motivator To become a successful Construction EquipmentRepairer you must be able to identify and utilize avariety of tools and Test, Measurement andDiagnostic Equipment (TMDE). Without thisknowledge you risk damaging tools, TMDE,equipment and possibly injuring personnel.

Learning Step/Activity NOTE: The instructor should inform the students of thefollowing Learning Step/Activity requirements. (TLO Step 2)

At the completion of this lesson, you [the student] will:

Action: Employ tools.

Safety Requirements The use of Personal protective Equipment (PPE) bystudents and instructors is mandatory during thispractical exercise. Further guidance concerning PPEcan be found in OSHA regulations 29 CFR 1910.132-.138; 29 CFR 1910.132-.133; 29 CFR 1910.132 and

138; and 29 CFR 1910.95.

Risk Assessment Low - Review the deliberate risk assessment, performa daily risk assessment, ensure it is recorded onappropriate forms, signed by authorized commandauthority, and posted at the training site(s).

Environmental Considerations No major environmental impact, training entirely of anadministrative or classroom nature, with little or noenvironmental impact on the environment, equipmentor personnel

Evaluation

Instructional Lead-InInform students of the Terminal Learning Objective(TLO) requirements. State the complete action,condition, standards safety, risk assessment level andenvironmental considerations. Explain the importanceof being able to identify and safely use and care fortools.

NOTE: Introduce the lessons topic to bediscussed.


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1. A demonstration of the proper use of toolsand an explanation of safety precautions.

2. A practical exercise on the proper use oftools.

ResourceRequirements

InsItructor

r Materials: I

LocalSOP(s)

Instructor Materials:

TM 9-243

SC 5180-90-N26

Local SOPs

Student Materials:

Student guides

Pens and pencils

Special Instructions Instructor Guidance

a. Ensure each station has the applicablemanufacturers reference as required.

b. Ensure all PPE is available at each station.

c. Ensure all required tools are available at thepertinent station.

d. Verify all students have removed all jewelryprior to beginning the PE.

e. Ensure each station has a copy of eachpractical exercise sheet and a TM 9-243.

f. Assist students as required.

g. Five minutes prior to the PE ending, stop andanswer any questions the students may have.

Determine if students have learned the material

presented by:

(a) Soliciting student questions and explanations.

(b) Asking questions and receiving answers fromthe students.

(c) Correcting student misunderstandings.


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Explain to students:

a. Inform students of the amount of timeallocated for this PE.

b. The practical exercise will consist of fourstations.

c The class will be divided among three of thefour stations.

d. You cannot go to station two prior tocompleting station one.

e. Breaks will be taken as required to use therestroom.

f. You must use TM 9-243 and follow theinstructors guidance at each station.

g. Safety equipment will be worn at eachstation.

h. Remove all jewelry. If you have a weddingband that cannot be removed, inform me soit can be taped up.

i. If you have any problem, raise your hand forassistance from an instructor.


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Procedures

Station One:

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

1. Properly install the blade in the hacksaw.

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

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

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

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

5. Select the correct drill twist size.

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

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

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

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

Station Two:

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

1. Properly position the metal in the vice.

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

2. Select the proper tap and die.


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

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

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

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

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


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SOLUTION FORPRACTICAL EXERCISE SHEET 62B10A07PE1

Station One:

Solution: The Student:

1. Used the TM to reference the proper use of the tools prior to beginning work.2. Properly installed the blade in the hacksaw, teeth forward.

3. Properly secured the metal in the vice and cut the round stock and bar stock to the specifiedlength.

4. Used the correct file and removed any rough edges or burrs from both items of metal.

5. Used the center punch to mark the bar stock for drilling.

NOTE: The student must be wearing safety goggles.

6. Selected the correct drill twist size.

NOTE: The drill must be unplugged when the student is installing or removing the drill twistfrom the drill.

7. Installed and secured the drill twist into the drill properly.

8. Properly drilled the hole without causing damage to the equipment or personal injury.

9. Used the file to remove any burrs or rough edges as required.

10. Removed the drill twist from the drill and placed it back in the set.

Station Two:

Solution: The student:

1. Used the TM for all of the following steps.

2. Properly positioned and secured the metal in the vice.

3. Selected the proper tap and die from the sets.

4. Inspected the items for defects or breakage.

5. Properly inserted the tap in the tap wrench.

6. Properly used the tap to cut internal threads in the piece of flat stock.

7. Properly used the die to thread the round stock.

8. Attached the threaded round stock to the threaded square stock.

9. Cleaned lubricated and returned the components to their sets.

Station Three:


1. Used the TM.

2. Inspected the tools for damage or serviceability.

3. Selected the proper size die block.

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

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


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6. Properly positioned the tubing in the die block.

7. Performed a single flare IAW the TM.

8. Turned the piece of tubing over and repeated steps # 5 and 6.

9. Selected the proper adapter and made a double flare to the tubing.

9. Inspected the flares for breakage or cracks.10. Re-flared the tubing if it was cracked or broken.

11. Cleaned and secured all tools when the exercise was complete.

Station Four:


1. Used torque specifications from a TM.

2. Explained the process as the TM prescribes it.

3. Include incremental step torque procedures.


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ELECTRICAL SYSTEMS

PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10B01 version ADT

PRACTICAL EXERCISE SHEET 62B10B01PE 1

Title Identify Wiring Schematics

Lesson Number / Title 62B10B01 version ADT / Electrical System

Introduction

Motivator Explain the importance of being able to pschematics and electrical symbols to the

Learning Step/Activity NOTE: The instructor should inform the studerequirements. (TLO Step 2)

At the completion of this lesson, you [the stud

Action: Identify wiring schematics.

Safety Requirements There are no safety considerations assoc

Safety alerts, warnings, and reinforcemenpoints in the lesson where safety issues a

Risk Assessment Low - Review the deliberate risk assessmensure it is recorded on appropriate formsauthority, and posted at the training site(s

Environmental Considerations No major environmental impact, training enature, with little or no environmental imp

personnel.

Evaluation Practical Exercise

Instructional Lead-In State the complete, safety, risk assessmeconsiderations.

Resource Requirements Instructor Materials:

* TC 9-60* TM 5-2420-224-10* TM 5-2420-224-20-1

* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P


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

Student Materials:

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

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

Special InstructionsBefore presenting this lesson, Divide clas

1. Group #1 will do a PE on learning


3. After 1 hour the groups will switch

4. Ensure all materials are on hand

Read and understand B01 TSP prior to

1. Ensure that students haveMW24C scoop loader an

2. Explain to students:

a. Each student is to work i

b. Fifteen minutes will be alExercise.

c. Following Problem #1, fivsolution with the instructo

d. Fifteen minutes will be al


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Exercise.

e. Following Problem #2, fivinstructor to review the

f. Fifteen minutes will be al

Exercise. Following Probthe instructor to review th

Assist students as required.


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Procedures

Identify Wiring Schematics:

Problem #1: Using the MW24C Scoop Loader schematic and the study guide identify either a symbolor a component as required.

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

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

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

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

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

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

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

8) Locate the ground at the negative battery cable.

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 switchidentifying 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 thepositive 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 lower30-amp circuit breaker. Next keep with the same red wire to the upper 30-amp circuit breaker. Goingthrough that circuit breaker pick up the two-red/black wires and trace them to the harness/cableconnector, pins 16 & 18 of the rear wiring harness. Continue through the connector to the front wiringharness on the same pin numbers and colored wires. Trace it over to the ignition key switch Batt.Terminal.

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


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Problem #3: Using a blue pen, trace the circuit that sends power from the ignition key switch toengage the starter motor, identifying components, wiring numbers and colors during theprocess.

Start at the ignition key switch. Look on the backside of the switch for the start terminal. Follow the whitewire to the neutral start switch. Go through the neutral start switch, leaving it on a VIO/BLK wire, going tothe 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. Thiswill energize the starter solenoid closing its contacts. Now trace the wire leaving the M terminal over tothe starter motor, go through the starter motor to the ground.


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SOLUTION FORPRACTICAL EXERCISE SHEET 62B10B01PE 1

There is no solution for this practical exercise. The object of this PE is for the student to gainproficiency in reading and utilizing wiring schematics.


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Title Identify the purpose of a battery, battery cenvironmental procedures.


Introduction

Motivator Explain the importance of being able to pconstructed, the operation of the battery,



Action: Identify the purpose of a basafety, and environmental p

Safety Requirements Risk of skin and eye injury exists during balong with connecting and disconnecting are given extensive instruction on how to warned of the dangers present. Each stuRisk of hearing damage exists during engand required to wear aural protectors. Emwill be available and their proper use demand instructors is mandatory during this pconcerning PPE can be found in OSHA reCFR 1910.132-.133; 29 CFR 1910.132 an


Environmental Considerations There is the potential for battery acid spillprocedures. The possibility exists for spillengine operations. Adequate ventilation when battery load testing and charging prguidance can be found in OSHA regulatio1910.1200.

Evaluation Practical Exercise.

Instructional Lead-In State the complete, safety, risk assessme

considerations.


* FM 11-60* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20


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* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 9-8000* TM 11-6625-3199-14* FOS 20* ITRO-B TSP* Wiring schematics* 29 CFR 1910.1200* 29 CFR 1910.132* 29 CFR 1910.133* 29 CFR 1910.136* 29 CFR 1910.138* 29 CFR 1910.95

Student Materials:

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

Special InstructionsBefore presenting this lesson, Divide clas



3. After 1 hour the groups will switch

4. Ensure all materials are on hand

Read and understand B01 TSP prior to


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1. Ensure that students havrubber gloves and safetybattery charger and batte


(a) The location of emergency sthey are used.

(b) Students will work in groups

(c) Twenty-five minutes will be aExercise.

(d) Following Problem #1, five msolution with the instructor.

(e) Ten minutes will be allotted f

(f) Following Problem #2, five mreview the solution.

(g) Ten minutes will be allotted f

(h) Following Problem #3, five mreview the solution.

3. During entire testing procedure

4. Assist students as required.


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Procedures

Problem #1 Perform a specific gravity test on a battery IAW TM 9-6140-200-14. Annotate the resultson the practical exercise work sheet in your study guide. When all students havecompleted 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, manufacturesinstructions and the appropriate technical manuals. Annotate the results on the practical exercise worksheet in your study guide. When all students have completed this task the instructor will go over theresults with the entire group.

Readings:BeforeDuringAfter


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Problem #3 Properly recharge a battery IAW the instructors guidance, manufactures instructions andthe appropriate technical manuals.

NOTE: Since battery chargers are not all alike, ensure you follow the instructors guidance whenconnecting the charger to the battery.

NOTE: The voltage in each battery depends on the condition of the batteries. The setup of thebattery chargers may vary depending on the type and capabilities of the charger. This is why it isvery important to use the manufacturers manual.


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There is no solution for this practical exercise. The object of this PE is for the student to gainproficiency in using battery testing and charging equipment.


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Title Identify TMDE used for electrical system


Introduction

Motivator Explain the importance of being able to psystem testing.



Action: Identify TMDE used for elec

Safety Requirements Risk of eye injury exists during power-up

Is required to wear eye protection when cSPORT power cable at the battery. Risk ooperation. Each student is required to weoperation. Risk of eye injury exists duringprocedures. Each student Is required to wdisconnecting the circuit board to the battthroughout the exercise. Emergency showavailable and their proper use demonstrainstructors is mandatory during this practiconcerning PPE can be found in OSHA reCFR 1910.132-.133; 29 CFR 1910.132 an

Risk Assessment Low - Review the deliberate risk assessm

ensure it is recorded on appropriate formsauthority, and posted at the training site(s

Environmental Considerations Instructors should complete a risk assessoperations, or logistical activities. Risk asidentifying potential environmental hazarddecisions, implement controls, and insure

Evaluation Performance Evaluation Practical Exercis

Instructional Lead-In State the complete safety, risk assessmeconsiderations.


* FM 11-60* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20


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* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 9-8000* TM 11-6625-3199-14* FOS 20* ITRO-B TSP* Wiring schematics

Student Materials:

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

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

Special Instructions1. Before presenting this lesson, divide

2. Group #1 will do a PE on the SPORT

3. Group #2 will do a PE on the Multime

4. After 2 hours 15 minutes the groups wminutes.

5. Ensure all materials are on hand and

Read and understand B01 TSP prior t

Procedures


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Group one:

1. Ensure that students have a study guide safety goggles and appropriate TM.

2. Assign students to a charging cart with a complete SPORT or MSD.


a) Students will work in groups of two.

b) Instruction will be lock step, allowing all students to have the opportunity to understandthe entire exercise.

c) During battery connect and disconnect procedures safety goggles will be worn.

d) During equipment operation hearing protection will be worn.

4. Assist students as required.


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Group one:

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

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

2. Perform battery voltage test.

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

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

5. Power down the SPORT or MSD.


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Group Two:

NOTE: Actual equipment may be utilized instead of circuit boards.

1. Ensure that students have a study guide, multimeter and a circuit board.


a) They will work individually.

b) They must utilize the multimeter set up for continuity to check all components mountedon the circuit boards to include conductors.

c) Properly connect all conductors so the turn signals and high/low beam lights will function.

d) Take completed circuit board to instructors table for operational test.

e) That they must answer questions pertaining to automotive electricity prior to their circuitboard being tested.


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Group two:

Utilize a multimeter along with the knowledge you have gained in the previous electrical classes toperform 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.

FeedbackRequirements


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There is no solution to this practical exercise. The object of this PE is for the student to gain proficiencyin using TMDE.


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Title Troubleshoot a starting and charging syst


Introduction

Motivator Explain the importance of being able to pcharging system..



Action: Troubleshoot a starting and

Safety Requirements1. Risk of eye injury exists d

required to wear eye prot

2. Risk of hearing injury durrequired to wear hearing

3. Risk of electrical shock e

4. The use of PPE by studethis practical exercise.

5. Further guidance concerregulations 29 CFR 1910CFR 1910.132 and 138;

Emergency showers and eyewash statuse demonstrated.


Environmental Considerations The possibility exists for spillage of fuel, operations. Adequate ventilation is requitroubleshooting a starting and charging syComply with Shop/Installation SOP/Opera

hazardous materials.

Evaluation Performance Evaluation Practical Exerci

Instructional Lead-In State the complete safety, risk assessmeconsiderations.


* FM 11-60


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* TM 5-2420-224-10* TM 5-2420-224-20-1* TM 5-2420-224-20-2* TM 5-2420-224-24P* TM 5-3805-261-20* TM 5-3805-261-24P* TM 5-3805-262-20* TM 5-3805-262-24P* TM 5-2410-237-10* TM 5-2410-237-20* TM 9-4910-571-12&P* TM 9-6140-200-14* TM 9-8000* TM 11-6625-3199-14* FOS 20* ITRO-B TSP* Wiring schematics

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

Special InstructionsNOTE: If specified equipment is not av

similar systems may be substitavailable a request for wavier asubmitted.

1. Before presenting this les

2. Explain that they will do asites

3. Students will receive 3 ho

4. Ensure all materials are o


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Procedures

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

1. Ensure that students have a study guide, PPE and appropriate TM.

2. Brief students on safety requirements for site.


a) Students will work as a group and full participation from each student is required.

b) Each student will demonstrate how to properly use the appropriate technicalmanual, electrical schematic and how to set up and perform tests with themultimeter.



e) Do not make any repairs with out approval of the instructor.



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


2. Brief students on safety requirements for site.

3. Explain to students the following tasks will be performed:

a) Reinforce locating components on MW24C wiring schematic

b) Locate components on the MW24C

c) Set multimeter up for the following measurements:

(1) Amperage DC

(2) Resistance

(3) Continuity

(4) Voltage DC

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

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

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


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


2. Brief student on safety requirements for site.



b) Each student will demonstrate how to properly use the appropriate technicalmanual and how to set up and perform tests with the SPORT or MSD.






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



3. Explain to students they will utilize a SPORT / MSD to diagnose the following situations:

a) On the D7G Dozer in DCA mode run the complete GO chain and the following testfrom 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 followingtest 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 systemtroubleshooting chart (PG 3-266 PARA 3-33)


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Site #3: Troubleshoot accessory circuits utilizing the digital multimeter:





b) Each student will demonstrate how to properly use the appropriate technical manualand how to set up and perform tests with the digital multimeter.






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Site #3: Troubleshoot accessory circuits utilizing the digital multimeter



3. Explain to students they will utilizing a digital multimeter to troubleshoot the followingfaults:

a) On the MW24C Scoop Loader, utilize a digital multimeter to troubleshoot the followingdeficiency: Lights inoperative

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

(1) EMS panel not working properly

(2) Blade float switch inoperative


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There is no solution for this practical exercise. The object of this PE is for the student to gain proficiencyin using TMDE to troubleshoot a starting and charging system.


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

Lesson Number

/ Title

62B10B01 version ADT / Electrical Systems

Introduction

Motivator Explain the importance of being able to properly replace a switch, replacebatteries, and repair a wiring harness.

LearningStep/Activity

NOTE: The instructor should inform the students of the following Learning Step/Activity

requirements. (TLO Step 6)


Action: Repair a wiring harness, replace batteries and replace a switch.

SafetyRequirements

Risk of skin and eye injury exist during battery disconnecting and connectingprocedures. The possibility of electrical shock also exists. All personnel will weareye protection. All jewelry of any kind (ID tags, watches, rings, etc) will beremoved. All personnel will be provided and required to wear aural protectorswhile equipment is running. Emergency showers and eyewash stations will beavailable and their proper use demonstrated. The use of Personal protectiveEquipment (PPE) by students and instructors is mandatory. Further guidanceconcerning PPE can be found in OSHA regulations 29 CFR 1910.132-.138; 29CFR 1910.132-.133; 29 CFR 1910.132 and 138; and 29 CFR 1910.95.

RiskAssessment

Low - Review the deliberate risk assessment, perform a daily risk assessment,ensure it is recorded on appropriate forms, signed by authorized commandauthority, and posted at the training site(s).

EnvironmentalConsiderations

Instructors should complete a risk assessment before conducting training,operations, or logistical activities. Risk assessments assist instructors inidentifying potential environmental hazards, develops controls, make riskdecisions, implement controls, and insure proper supervision and evaluation.

Evaluation Achieve a GO on a performance evaluation in the time allotted.

InstructionalLead-In

State the complete safety, risk assessment level, and environmentalconsiderations.



TM 5-3805-261-20

TM 5-3805-262-20

TSP 62B10B01

Student Materials:

TM 5-3805-261-20

TM 5-3805-262-20


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SpecialInstructions

NOTE: If specified equipment is not available for training equipment withsimilar systems may be substituted. If similar systems are notavailable a request for wavier and supporting lesson plans must besubmitted.

Before presenting this lesson, divide class into equal groups.

Explain that they will do a round robin.

Ensure all materials are on hand and in quantities needed.

Ensure that students have a study guide, Personal Protective Equipment, andappropriate CD for the SPORT/MSD or TM reader.

Brief students on safety requirements for site.

Explain site requirements to students.

Students will work as a group and full participation from each student is required.

Student will demonstrate how to properly use the appropriate technical manual,SPOR/MSD or TM reader.Student will demonstrate their knowledge in inspecting, testing, and repairing awiring harness and switch, and replacing a battery on a scoop loader.

During battery connect and disconnect procedures PPE will be worn.

During equipment operation hearing protection will be worn.

Repairs will not be made without the approval of the instructor.



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Procedures

Station # 1:

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


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Station # 1:

Students should have used the TM to locate the fault "Bucket does not return to digging position" andfollowed the procedures outlined to determine the Return to Dig Switch is faulty. Student should havefollowed the procedures outlined in the TM to replace the switch and verified the fault was corrected.

Station # 2:

Students should have used the TM to locate the fault "Engine does not crank" and followed theprocedures outlined to determine the batteries are faulty. Student should have followed the proceduresoutlined in the TM and explained to the instructor the proper procedure to replace the batteries.

NOTE: Instructor will insure the student understands the correct procedures to disconnect thebatteries, remove the battery hold down bracket(s), remove the batteries, replace and reconnectthem. Batteries will not be physically removed.

Station # 3:

Students should have used the TM to locate the fault "All driving, tail and panel lights fail to operate" andfollowed the procedures outlined to determine a wire in the wiring harness is faulty. Students should havefollowed the instructor's guidance, repaired the faulty wire and verified the fault was corrected.


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DIESEL ENGINE SYSTEMS

PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 62B10C01 version ADT

PRACTICAL EXERCISE SHEET 62B10C01 PE1

Title Disassemble a diesel engine.

Lesson Number/ Title

62B10C01 version ADT / Diesel Engine Systems

Introduction At this station, you have Caterpillar 3304 four-cycle diesel engines. You will usethe supplied technical manual and your instructors guidance to disassemble theengines.

Motivator In order to be a competent construction equipment repairer you must understandand be able to perform diesel engine repair and adjustments. During this practicalexercise you will be introduced to some the techniques used to do this.


NOTE: The instructor should inform the students of the following Learning Step/Activityrequirements. (TLO Step 2)


Action: Disassemble a diesel engine.

SafetyRequirements

Risk of hand and foot injury while handling heavy engine components and usingspecial purpose tools and equipment. Foot and hand protection is required duringthese operations. Students are given extensive instructions on how to properlycomplete these operations and are warned of the dangers. Risk of hearingdamage during engine operation. Hearing protection is required during engineoperation. Risk of eye injury while working with POL products. Eye protection isrequired during these operations. The use of PPE by students and instructors is

mandatory during this practical exercise. The use of Personal ProtectiveEquipment (PPE) can be referenced in Occupational Safety and HealthAdministration (OSHA) regulation 29 CFR 1910.132-.138. Each student is briefedon the location and operation of the eye wash station. An instructor must be onsite to supervise and to ensure safety equipment is used and procedures areadhered to during all operations.

RiskAssessment

Low


Potential environmental contamination through oil and fuel spilled during enginedisassembly. Students are briefed on proper disposal of POL products and how toproperly clean up spills. Ensure spill kits are available and there location identified.


Evaluation Written examination and performance evaluation.

InstructionalLead-In

NOTE: Briefly review the general safety requirements, risk assessments,and environmental considerations associated with this lesson.


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Explain to students

a. Safety is a top priority and will be monitored and enforced throughout thispractical exercise.

b. This PE is eleven hours long.

c. You will be working in groups of four.

d. If you have any questions or problems during this PE contact an instructor priorto continuing.



OMRG25204 Operation and Maintenance Manual May 96

OMRG24828 Operation and Maintenance Manual Jan 96

OMRG25205 Operation Manual May 96

CTM86 Component Technical Manual Jul 99

CTM104 Component Technical Manual Oct 98

PC2527 Parts Catalog Jun 99

PC2521 Parts Catalog Sep 99

6SE201 Service Manual Feb 84

PME201 Parts Manual Oct 77

SENR2569-03 Systems Test and Adjustment Feb 98

SENR1189 Disassembly and Reassembly Jul 96

29 CFR 1910.1200 Hazard Communication 01 Jul 2003

29 CFR 1910.132 Personnel Protective 01 Jul 2003Equipment General Requirements

29 CFR 1910.133 Eye and Face Protection 01 Jul 2003

29 CFR 1910.136 Foot Protection 01 Jul 2003

29 CFR 1910.138 Hand Protection 01 Jul 2003

29 CFR 1910.95 Occupational Noise 01 Jul 2003Exposure

Eye Protection


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Student Materials:

Student Study Guide

Equipment manuals extracts (1:4)

Situation Sheets (1:4)

Eye Protection

Safety Boots

Rubber Gloves

Rubber Apron

Coveralls

SpecialInstructions

NOTE: Reinforce the safety procedures throughout this Practical Exercise.During the practical exercise ask the students questions pertainingto each system and individual components. This will verify theyunderstand what makes up each system and what each component sfunction. If the students make an error in the procedures, stop andinform the students of the error before continuing.


a. Safety

i. Ensure a safety briefing is conducted for each site asapplicable.

ii. Ensure safety is monitored and enforced throughout

this practical exercise.

b. Ensure each station has the applicable TMs andmanufacturers references as required.

c. Ensure all personal protective equipment (PPE) is available atthe appropriate stations.

d. Ensure all required tools and TMDE are at each station.

e. Divide class into groups of four.

f. Ensure each station has a copy of the practical exercise sheetpertinent to that station.

g. Station requirements. The requirements for this station are:

i. One technical manual (SENR1189, July 1996)ii. Situation Sheet #1 and Situation Sheet #2iii.One torque wrenchiv.Fuel for each enginev.One set of batteriesvi.One general mechanics tool box


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h. Assist students as required.

Procedures

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

1. DISASSEMBLY OF ENGINE

A. REMOVAL OF ELECTRICAL SYSTEM COMPONENTS

1) Removal of Alternator

a. Tag all wires connected to alternator to ensure proper installationduring reassembly.

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

c. Loosen mounting bolts and support bracket bolts. Move alternatortowards engine to loosen drive belts.

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

e. Remove alternator, alternator support bracket and all mounting nuts,bolts/spacers. Place support bracket, nuts/bolts and spacers in canmark 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 duringreassembly.

b. Remove wire-mounting nuts from positive and negative posts ofstarter. Remove wire-mounting screw from solenoid.

c. Remove positive and negative wires (large black leads) and solenoidwire from starter. Gather all loose wiring together and fold back ontoengine stand behind slave cable connector. DO NOT leave wiring onfloor.

d. Reinstall wire mounting nuts and screw on starter.

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

NOTE: Starter weighs 65 pounds.


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f. Remove starter from engine and wrap in white mat and place on topof workbench. Have students retain starter mounting bolts andgasket 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 gearshaft support bracket facing out using starter gasket and three (3)starter mounting bolts. Tighten starter bolts using 5/8 boxed-endwrench.

b. Insert small end of geared shaft into hole in support bracket. Gearedend must engage ring gear on flywheel.

c. When complete, small-geared end of shaft should engage flywheelring gear and shaft should move freely in and out of hole. Lubricateshaft 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 itis accomplished to the instructor.

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

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

NOTE: Ask students, "Why must the engine be rotated clockwise?" The answer is to remove playfrom the timing gears.

2) Students will utilize the 1/2" ratchet for this procedure. Ratchet will be replacedin bottom of toolbox when procedure is completed.

3) To achieve 30 clockwise rotation, place ratchet in end of turning tool withhandle of ratchet pointed down and touching the side of engine. Pull up onhandle and rotate engine with ratchet until ratchet handle is all the way up andtouching the side of engine. Ratchet will be turned seven (7) times in thismanner 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 andplace in can marked FUEL INJECTION PUMP & GOVERNOR.

6) Insert 3/8" bolt in timing bolt hole and have students rotate enginecounterclockwise while applying finger pressure to 3/8" bolt. When bolt slidesinto hole provided in flywheel, the No. 1 piston is at top center.

7) Students will check rocker arm assembly per instructions in manual todetermine 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 checkingthe rocker arm assemblies of No. 1 piston. If timing is incorrect, ask studentshow they checked timing and which rocker arm assembly is for No. 1 piston.Explain procedure for checking timing and have students remove bolt fromtiming hole, slightly rotate engine counter-clockwise, reinsert bolt in timing hole,and continue to rotate engine until bolt slides into flywheel again. Instructor willcheck engine to insure correct timing.

C. REMOVAL OF AIR INDUCTION SYSTEM COMPONENTS

1) Removal of Air Cleaner Assembly

a. Loosen large hose clamp (on turbocharger side) of rubber couplingconnecting air cleaner to turbocharger.

b. Remove two (2) nuts and two (2) bolts holding air cleaner assemblyto 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 atend of work bench with filter housing on floor and elbow turnedunderneath 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 carefullypull it out of the turbocharger.

e. Leave gasket in place on intake manifold and reinstall bolts in intakemanifold. 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 exhaustpipe to exhaust manifold.

b. Hold exhaust pipe to turbocharger coupling and remove exhaust pipeand coupling from turbocharger as a unit. (Coupling is cast metaland may crack or break if dropped).

c. Place exhaust pipe and coupling assembly on workbench and pullcoupling from exhaust pipe.


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

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

f. Reinstall nuts and bolts on exhaust manifold and place large plasticcap 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 toturbocharger.

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 removetube 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 poorany 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 caplarge enough to fit over threads on fitting.

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

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

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

k. Reinstall nuts/bolts and gasket (if removed) in exhaust manifold.Cover/tie off opening in exhaust manifold and place cap in oil returntube 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 useblack bucket provided to drain system of water. Buckets will bedumped outside, away from building.

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


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

d. Remove mounting bolts to BOTH sections of fan guard, remove fanguard, place on floor under workbench, and reinstall bolts in radiatorshroud.

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

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

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

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

h. Remove two (2) long bolts (one at bottom right, one at top left) fromwater pump housing.

i. Pull water pump away from engine and remove.

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

k. Cover/tie off all exposed openings on pumps and engine. Placewater 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 removegasket between temperature regulator housing and cylinder head.

c. Remove water temperature regulator from engine, place insideregulator housing, wrap housing in rag and place in can markedTEMP REG.

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

E. REMOVAL OF FUEL SYSTEM COMPONENTS

1) Removal of Fuel Injection Lines

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

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

a. Students will utilize 3/4" line wrench to loosen all fuel injection linenuts beginning with No. 1 injector line at the fuel injection pumphousing. Loosen all nuts on the fuel pump from front to rear.


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b. Loosen the fuel injection line nuts at the fuel injection valves workingfrom front to rear. Hold the top of each fuel injection valve with a15/16 wrench and loosen fuel injection line nut with a 3/4" linewrench.

c. Once all nuts are loosened, screw all nuts off by hand. Graspinjector line assembly, lift up and invert assembly over engine toprevent excess fuel spillage, and place inverted assembly onworkbench.

d. Install screw-in type protector caps on ends of fuel line nuts andplace assembly carefully on shelf.

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

f. Place fuel injection line assembly underneath workbench. DO NOTplace 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 fueltransfer pump and remove. Loosen fuel line nut on fuel return lineconnected to the fuel injection pump. Cover/plug ends of supply andreturns lines. Place fuel supply line underneath the workbench andensure students do not set anything on top of it. Fold fuel return linedown along side of engine stand. Do not let fuel return line hang orlay on floor.

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

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 filteris loosened, unscrew it from the base with one hand while supportingit 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 filterand sides of can. Cover top of can with rag. This will prevent thefilter from tipping and spilling and will keep contaminants out of fuel.

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

NOTE: Insure students use dry sweep to clean up any fuel spilled at this point.

3) The following components/accessories must be removed prior to removing theFuel Injection Pump and Governor Assembly. Students in each group shouldwork individually or in pairs to accomplish these tasks.

a. Remove two (2) bolts securing exhaust manifold heat shield tomounting brackets. Place heat shield underneath workbench.


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b. Loosen nut on end of tube between air inlet elbow and air/fuel ratiocontrol. Remove line and cap/plug both ends. Cap fitting on air/fuelration control. Place line under workbench. DO NOT place anyother 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 toengine block and fuel injection pump. Remove support bracketensuring all O-rings are accounted for. Wrap support bracket in ragsand 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 nutsand washers in timing gear cover on workbench. Timing gear coverwill be reinstalled once fuel injection pump is removed.

f. Use a 15/16" socket and breaker bar and push downward to loosendrive gear bolt. Remove bolt and washer by hand and place in canmarked 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. Ifit is not loose, INSTRUCTOR will utilize gear puller to free it.

4) Removal of Fuel Injection Pump and Governor Assembly

NOTE: Fuel Injection Pump weighs approximately 53 lbs.

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

a. Fuel pump is mounted to engine using three studs with washers andnuts. Use a 9/16 boxed-end wrench to remove the BOTTOM two (2)

nuts and washers. One student will support fuel pump while the TOPnut and washer is removed using the following tool combination INORDER: 9/16 socket, 5" and 10" extension, universal joint andspeeder bar. Two (2) students will carry the fuel injection pump tothe workbench.

NOTE: Instructor will monitor students as fuel pump and governor assembly is removed fromstuds and placed on workbench.

b. Fuel injection pump will be positioned on workbench the back ofpump rests on short wooden block provided. Position pump onworkbench, 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 thepresence of two (2) O-ring seals. If any O-ring is missing, look for iton and around engine or on the ground. If it cannot be found,replace.

NOTE: Ensure students use dry sweep to clean up any fuel spilled at this point.


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d. Cover entire fuel pump with large rag. Reinstall timing gear cover onengine and hand tighten nuts. Cover/tie off opening where the fuelinjection 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 andNo. 2 cylinders and between the No. 3 and No. 4 cylinders and placein EXH MAN can.

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

NOTE: Exhaust manifold is heavy and fragile.

c. Using a two-person carry, carefully remove exhaust manifold fromengine 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 ragand place in EXH MAN can.

e. Place rag in each hole of cylinder head created by removal ofexhaust manifold. Do not let rags hang down below cylinder head.

G. REMOVAL OF ROCKER ARM ASSEMBLY AND PUSH RODS

1) Removal of Rocker Arm Assembly

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

b. Make six (6), one (1) ft square rags and remove any loose hangingthreads 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 toavoid 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 overtighten locknuts. This will prevent a bent valve or push rod duringinstallation of the rocker arm assembly.

NOTE: Bolts have 150 ft lbs of torque. Student using breaker bar will have another studentbehind 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 thecenter and moving alternately left and right until all are loose. Utilizespeeder wrench to free all bolts from threads but do not remove boltsfrom assembly.


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e. Place one hand under each end of the rocker arm shaft, lift upslightly, shake assembly to ensure push rods do not stick to rockerarms, and then lift assembly out of cylinder head. Place assembly,with threaded ends of bolts pointed down, in valve cover. Coverassembly 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 torear

c. Lift up slightly on push rod (approx. 1/2"), shake rod to insure it is notstuck to lifter, and lift out of engine.

d. Wipe off with rag and place in holed wooden block. Ensure rods areremoved and placed in wooden block in the proper order. Place ragsback 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 fromthe center. Use a V or W pattern moving alternately left and rightaway from center until all are loose. Utilize speeder wrench to freeall bolts from threads. As bolts and washers are removed placethem, head end first, in can marked HEAD BOLTS. Ensure washersremain on bolts.

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

c. Remove air cleaner support bracket and place on shelf. Reinstallbolts and washers on cylinder head.

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

e. Position hoist so that chain and hook at end of lifting beam iscentered over cylinder head. Attach lifting shackle to eye hooks on

cylinder head and hook on lifting beam. Be careful not to strikecylinder head.

f. Pump handle to REMOVE SLACK from chains and recheck hoist toinsure it is centered over cylinder head.

g. One student will stand on each side of cylinder head with hands onTOP of cylinder head and guide it as it is lifted. Instructor will operatehoist.


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NOTE: Cylinder head weighs 142 lbs. Warn students not to place fingers or hands under cylinderhead 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. Wheel cylinder head to work bench and position it over two (2)wooden blocks placed at each end of head.

j. Students will guide cylinder head as it is slowly lowered onto woodenblocks. Ensure blocks are positioned so they don't rest on valves.Caution students once again to keep hands and fingers from undercylinder head. Disconnect hoist and lifting shackle. Removeeyebolts and cover head with rags.

k. Remove head gasket from engine block at cylinder side being carefulnot to damage gasket. Wipe down and place behind cylinder head.

2) Removal of Cylinder Head Spacer Plate

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

b. Remove ALL water seals and one (1) O-ring in spacer plate andplace in can marked TAGS. Remove rags from holes in spacerplate.

c. Students will take hold of each end of spacer plate and lift it straightup from the block. Wipe down spacer plate and place behindcylinder head.

d. Carefully remove spacer plate gasket from engine. Wipe downgasket and place gasket behind cylinder head.

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


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SOLUTION FORPRACTICAL EXERCISE SHEET 62B10C01 PE1

There are no set solutions for this practical exercise. These engines do not have induced faults. The solepurpose of this period of instruction is to provide the students with the experience of using the referencesand to familiarize them with various engine subsystems.


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PRACTICAL EXERCISE SHEET 62B10C01 PE2

Title Reassemble a diesel engine.

Lesson Number

/ Title

62B10C01 version ADT / Diesel Engine Systems

Introduction At this station, you have Caterpillar 3304 four-cycle diesel engines. You will usethe supplied technical manual and your instructors guidance to reassemble theengines.

Motivator In order to be a competent construction equipment repairer you must understandand be able to perform diesel engine repair and adjustments. During this practicalexercise you will be introduced to some the techniques used to do this.


NOTE: The instructor should inform the students of the following Learning Step/Activityrequirements. (TLO Step 3)


Action: Reassemble a diesel engine.

SafetyRequirements

WARNING: Although there are no induced faults in the engines it ispossible for one of the systems on the engines to fail through mistakesmade by the students during reassembly.

Risk of hand and foot injury while handling heavy engine components and usingspecial purpose tools and equipment. Foot and hand protection is required duringthese operations. Students are given extensive instructions on how to properlycomplete these operations and are warned of the dangers. Risk of hearingdamage during engine operation. Hearing protection is required during engineoperation. Risk of eye injury while working with POL products. Eye protection is

required during these operations. The use of PPE by students and instructors ismandatory during this practical exercise. The use of Personal ProtectiveEquipment (PPE) can be referenced in Occupational Safety and HealthAdministration (OSHA) regulation 29 CFR 1910.132-.138. Each student is briefedon the location and operation of the eye wash station. An instructor must be onsite to supervise and to ensure safety equipment is used and procedures areadhered to during all operations.

RiskAssessment

Low



Evaluation Inform the students that the critical tasks of replacing the fuel line, fuel filter, fuelpump, injector pump, hand primer pump, air filter, turbocharger, oil line, waterpump, thermostat, drive belts, engine cooling fan, radiator and coolant hose will beevaluated during this practical exercise.

InstructionalNOTE: Briefly review the general safety requirements, risk assessments,and environmental considerations associated with this lesson.


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Lead-In

Explain to students

a. Safety is a top priority and will be monitored and enforced throughout thispractical exercise.

b. This PE is eighteen hours long.

c. You will be working in groups of four.

d. If you have any questions or problems during this PE contact an instructorprior to continuing.



OMRG25204 Operation and Maintenance Manual May 96

OMRG24828 Operation and Maintenance Manual Jan 96

OMRG25205 Operation Manual May 96

CTM86 Component Technical Manual Jul 99

CTM104 Component Technical Manual Oct 98

PC2527 Parts Catalog Jun 99

PC2521 Parts Catalog Sep 99

6SE201 Service Manual Feb 84

PME201 Parts Manual Oct 77

SENR2569-03 Systems Test and Adjustment Feb 98

SENR1189 Disassembly and Reassembly Jul 96

29 CFR 1910.1200 Hazard Communication 01 Jul 2003

29 CFR 1910.132 Personnel Protective 01 Jul 2003Equipment General Requirements

29 CFR 1910.133 Eye and Face Protection 01 Jul 2003

29 CFR 1910.136 Foot Protection 01 Jul 2003

29 CFR 1910.138 Hand Protection 01 Jul 2003

29 CFR 1910.95 Occupational Noise 01 Jul 2003Exposure

Eye Protection

Hearing Protection


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Student Materials:

Student Study Guide

Equipment manuals extracts (1:4)

Situation sheets (1:4)

Eye Protection

Safety Boots

Rubber Gloves

Rubber Apron

Coveralls

SpecialInstructions

NOTE: Reinforce the safety procedures throughout this Practical Exercise.During the practical exercise ask the students questions pertainingto each system and individual components. This will verify theyunderstand what makes up each system and what each component sfunction. If the students make an error in the procedures, stop andinform the students of the error before continuing.


Instructors guidance

a. Safety

i. Ensure a safety briefing is conducted for each site asapplicable.

ii. Ensure safety is monitored and enforced throughoutthis practical exercise.

b. Ensure each station has the applicable TMs andmanufacturers references as required.

c. Ensure all personal protective equipment (PPE) is available atthe appropriate stations.

d. Ensure all required tools and TMDE are at each station.

e. Divide class into groups of four.

f. Ensure each station has a copy of the practical exercise sheetpertinent to that station.

g. Station requirements. The requirements for this station are:

i. One technical manual (SENR1189, July 1996)ii. Situation Sheet #1 and Situation Sheet #2


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iii.One torque wrenchiv.One can of fuel for each enginev.One set of batteries

h. Assist students as required.


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Procedures

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

1. REASSEMBLY OF ENGINE

NOTE: Instructor will guide student through Practical Exercise.

A. INSTALLATION OF CYLINDER HEAD AND SPACER PLATE

1) Installation of Cylinder Head Spacer Plate

a. Thoroughly clean the spacer plate gasket, spacer plate, and cylinderblock with clean rags. Ensure all fluid is removed from head boltholes in the block.

b. Install yellow o-ring on oil tube on top of cylinder block. Install spacerplate gasket on cylinder block, ensuring ALL holes in gasket arealigned with holes on cylinder block.

c. Install spacer plate on the cylinder block. Spacer plate must belowered straight down on the cylinder block.

d. Install yellow o-ring on oil tube on top of spacer plate. Install waterseals in appropriate holes on spacer plate. Ensure smaller waterseals ARE NOT placed in cylinder head bolt holes on block (look forthreads 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 ingasket are aligned with holes on spacer plate.

b. Remove ALL rags from cylinder head and place them on theworkbench. They will be used again once the cylinder head is backon the engine block.

NOTE: Cylinder head weighs 142 pounds.

c. Attach engine hoist to cylinder head. Lift cylinder headapproximately 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 thecylinder head to ensure nothing is hanging below the bottom of thecylinder head.

NOTE: Foreign material caught between the cylinder head and engine block could cause seriousdamage to equipment.


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

f. Slowly lower the cylinder head onto the engine block. Ensurestudents know to guide the dowels at each end of the engine blockinto 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 arehand tight. Install 5 smaller intake manifold bolts and screw them inuntil they are hand tight.

h. Using rags removed from cylinder head before installation, cover/tieoff 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 frontof the engine to the rear.

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

c. Using a flashlight, guide the end of the push rod on to the TOP of thelifter it originally came off of.

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

d. Once push rods are installed, place one rag in each hole the pushrods 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 itfrom 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 appropriatebolt holes. Once bolts are aligned with bolt holes, lower rocker armassembly, making sure the rocker arms engage the valves and thepush rods.

d. Once rocker arm assembly is in place and the rocker arms areengaged with the push rods, screw in rocker arm assembly bolts untilthey 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, pg70). Instruct students to become familiar with torque sequence.

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

NOTE: Instructor will show students the proper use of the torque wrench.

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

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

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

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


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b. Clean all gasket surfaces around exhaust ports on cylinder head andexhaust manifold.

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

NOTE: Instructor will tell students to hold exhaust manifold up against the cylinder head untilwashers and nuts are installed on the first and last studs.

d. Put exhaust manifold in position on studs. Install washers and nutson 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 andNo. 4 cylinders with the holes for bolts on top. Install the remainderof the washers and nuts.

f. Torque ALL manifold nuts to 25 lb ft.

D. INSTALLATION OF FUEL SYSTEM COMPONENTS

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

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

1) Timing of Fuel Injection Pump and Governor Assembly

a. Remove the bolts in the timing pin cover in position. Remove thecover 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 thefuel injection pump camshaft without the washer. This will allow thecamshaft in the fuel system to be turned.

d. Put pressure on the end of the timing pin and turn the camshaftslowly 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. 1cylinder.

NOTE: Instructor will ensure timing pin is NOT removed

e. Leave the timing pin in position in the groove (slot). Remove the boltfrom the end of the camshaft. Place bolt back in FUEL INJ PUMPcan.


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2) Install the Fuel Injection Pump and Governor Assembly

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

a. Remove timing gear cover and rags covering holes.

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

c. Ensure the O-rings stay in place and position the fuel injection pumpon the engine. Making sure the fuel injection pump camshaft slidesinto the hole in the fuel injection pump drive gear.

d. Install the three (3) nuts on studs to hold the fuel injection pump tothe engine. Install the two (2) bolts that screw into the bottom of thefuel injection pump. Tighten all nuts and bolts until tight. DO NOTOVER-TIGHTEN.

e. Install bolt that secures fuel injection pump drive gear to fuel injectionpump camshaft. Torque bolt to 100 lb ft.

NOTE: Instructor will verify the bolt was torqued properly.

1) The following components/accessories must be installed after installing theFuel Injection Pump and Governor Assembly. Students in each group shouldwork individually or in pairs to accomplish these tasks.

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

b. Install tube between air inlet elbow and air/fuel ratio control. Only the

end of the line connecting to the air/fuel ration control can bemounted. 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 NOTOVER-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. Lubricatefuel 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 fuelfilter gasket makes contact with the base, tighten the filter anadditional 1/2 turn.


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c. Install and tighten fuel inlet (between the primary filter and fueltransfer 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 injectionline nuts until they are finger tight.

c. Students will utilize 3/4" line wrench to tighten all fuel injection linenuts beginning with No. 1 injector line at the fuel injection pumphousing. Tighten all nuts on the fuel injection pump from front torear.

d. Tighten the fuel injection line nuts at the fuel injection valves workingfrom front to rear. Hold the top of each fuel injection valve with a15/16 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 forcylinders 1 and 2. Use a thickness gauge to set clearance.Clearance will be set to 0.015. Clearance will be checked with0.017. 0.015 blade will drag slightly between the rocker arm andthe top of the va

2005 us army construction equipment repairer instructor's guide 193p

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