reportr e sumes - eric · reportr e sumes. ed 021 119. vt 006 006. automotive diesel maintenance....

REPORTR E SUMESED 021 119 VT 006 006AUTOMOTIVE DIESEL MAINTENANCE. PROGRAM OUTLINE.HUMAN ENGINEERING INSTITUTE, CLEVELAND, OHIO

PUB DATE I. MAR 68EDRS PRICE MF-$0.25 HC-$0.96 22P.

DESCRIPTORS- *CURRICULUM GUIDES, *TRADE AND INDUSTRIALEDUCATION, MOTOR VEHICLES, *AUTO MECHANICS (OCCUPATION),*DIESEL ENGINES, ADULT VOCATIONAL EDUCATION, TRANSPARENCIES,PROGRAMED MATERIALS, INDIVIDUAL INSTRUCTION, INSTRUCTIONALFILMS, PROGRAMED INSTRUCTION, EQUIPMENT MAINTENANCE,

INFORMATIONAL TOPICS COVERED IN THE TEXT MATERIALS ANDSELF-INSTRUCTIONAL BRANCH PROGRAMED TRAINING FILMS FOR A2-YEAR, 55 MODULE PROGRAM IN AUTOMOTIVE DIESEL MAINTENANCEARE GIVEN. THE 30 MODULES FOR "AUTOMOTIVE DIESEL MAINTENANCE1" ARE AVAILABLE AS VT 005 655 - VT 005 684, AND THE 25MODULES FOR "AUTOMOTIVE DIESEL MAINTENANCE 2" ARE AVAILABLEAS VT 005 685 VT 005 709. THIS DOCUMENT IS AVAILABLE FROMTHE HUMAN ENGINEERING INSTITUTE, HEADQUARTERS AND DEVELOPMENTCENTER, 2341 CARNEGIE AVENUE, CLEVELAND, OHIO 44115. (HC)

STUDY AND READING MATERIALS

AUTOMOTIVE

MAINTENANCEU.S. DEPARTMENT OF HEALTH, EDUCATION & WRFARE

OFFICE OF EDUCATION

THIS DOCUMENT HAS BEEN REPRODUCED EXACTLY AS RECEIVED FROM THE

PERSON OR ORGANIZATION ORIGINATING IT. POINTS OF VIEW OR OPINIONS

STATED DO NOT NECESSARILY REPRESENT OFFICIAL OFFICE OF EDUCATION

POSITION OR POLICY.

PROGRAM OUTLINE

HUMAN ENGINEERING INSTITUTE11=111

AUTOMOTIVE MAINTENANCE -- YEAR I

TextIndividualized Instruction

With Didactor

AM 1.-1 GENERAL INTRODUCTIONTO DIESEL ENGINESA. Diesel engines vs

gasoline enginesB. Air supply for the

dieselC. Fuel supply for the

dieselD. Lubricating the dieselE. Cooling the dieselF. Advantages of dieselsG. Mechanical features

AM 1-2 MAINTAINING THE AIRSYSTEM -- DETROITDIESEL ENGINESA. Operation and functionB. The air cleaner oil bath

cleaner and dry typecleaner

C. Air shutdown housingD. Exhaust systemE. The blowerF. The turbochargerG. Troubleshooting tips on the

air system

AM 1-3 MAINTAINING THE FUELSYSTEM DETROIT DIESELENGINESA. Purpose of the fuel systemB. Tracing the fuel flowC. Minor components of the fuel

systemD. Maintenance tipsE. Construction and function of

the fuel injectorsF. Troubleshooting tips

1/3/68

DIESEL AUTOMOTIVE MAIN-TENANCE -- GENERALINTRODUCTIONDiesel engine vs gas enginesimilar components -- com-pression differences -- fuelssafety advantages/disadvantagestwo cycle vs four cycle -- Rodtsblower (basic) -- air turbulencecombustion chamber shapes

DIESEL AUTOMOTIVE MAINTENANCE -- DETROITDIESEL AIR SYSTEMConcept of afat in relation to solids/liquids -- atmospheric pressurepsi -- sea level vs altitudevacuum -- manometer -- psigabsolute pressure -- air and thediesel -- air and the blowerexhaust back pressure -- testingwith a manometer

MAINTAINING THE FUELSYSTEM -- DETROIT DIESELBasic characteristics of fuelcetane numbers -- viscositydistillation -- sulfur contentfuel specificatons -- diesel fuelspecifications -- abnormal engineperformance due to fuel

Automotive Maintenance -- Year I


With Didactor

AM 1-4 MAINTAINING THE COOLINGSYSTEM -- DETROIT DIESELENGINESA. Purpose of cooling systemB. Care and maintenance of the

cooling systemC . Cooling system componentsD. Troubleshooting tips

AM 1-5 MAINTAINING THE LUBRI-CATION SYSTEM -- DETROITDIESEL ENGINESA. Lube oils usedB. Maintenance of the lubri-

cation systemC. Crankcase ventilation

components

AM 1-6 MAINTAINING MECHANICALGOVERNORS - - DETROITDIESEL ENGINESA. Types of governors and

engine locationB. Governor applicationsC. Limiting speed mechanical

governor (in-line and V-71series)

D. Variable speed mechanicalgovernor (in-line and V-71series)

E. Constant speed mechanicalgovernor (i&-line 71)

AM 1-7 ENGINE TUNE-UP: DETROITDIESEL ENGINESA. Scheduling tune-upsB. Tune-up procedures

DIESEL AUTOMOTIVE MAIN-TENANCE -- HEAT TRANSFERPrinciples of heat transfer --convection -- conductionradiation -- heat dissipationthermal conductivity -- heatdissipation in diesel engines

BASIC ENGINE LUBRICANTCHARAC TERIS TIC SLubricant deterioration indiesels -- oxidation -- organicacids -- varnish -- sludgechemical characteristics ofoil -- additives -- viscositydetergents -- SAE designation --Conradson test

MECHANICAL PRINCIPLESOF GOVERNOR OPERATIONCentrifugal force ofgovernor flyweights springtension decreased loadsincreased loads -- fuel control --fulcrums -- pivots mechanicaladvantage -- governor failures

ENGINE TUNE -UP--DETROITDIESEL ENGINEWhen a tune-up is requiredtemperature of engine and tune-up -- importance of sequenceexhaust valve clearancetiming the fuel injectorsgovernor gap -- injector rack --maximum no-load speed r idlespeed -- adjusting the buffer screwlinkage and throttle movement



With Dida.ctor

AM 1-8

AM 1-9

ENGINE COMPONENTS - --PARTA. Cylinder assembly

(liners)B. Cylinder headC. Valves and valve mech-

anismsD. Piston and piston rings

ENGINE COMPONENTSPART IIA. Shafts and bearingsB. CamshaftsC. Bearings and their main-

tenanceD. Detecting failure

AM 1-10 USE OF MEASURING TOOLSIN DIESEL MAINTENANCEA. Linear measureB. Measuring with rules and

tapesC. Getting precision with

micrometersD. Dial indicatorsE. TachometersF. Torque wrenchG. Thickness (feeler)

gageH. Valve repair equipment

AM 1-11 PART I - MAINTAINING THEFUEL SYSTEM -- CUMMINSDIESEL ENGINES (part 1)A. Review of two cycle and four

cycle conceptB. Some basic characteristics of

four cycle enginesC. The Cuinmins fuel systemPART UNIT REPLACEMENT(ENGINE/A. Preparation for removal136 Unit removal

ENGINE COMPONENTS --PART ICombustion -- ignition -- air-fuel ratios -- ignition delayturbulence -- temperaturesfuel qualities -- smoke analysis

ENGINE COMPONENTS --PART IIBearings and the diesel enginethrust -- radial loads -- axialloads -- journal bearingsfriction heat dissipationcrankshaft bearing loads for twocycle engines bearing loads forfour cycle engines -- ballbearings -- need;e bearingsroller bearings -- care of bearings

USE OF MEASURING TOOLSIN DIESEL MAINTENANCETools and the diesel mechanicshop math -- micrometers(inside, outside, depth)reading micrometers --problems

UNDERSTANDING BASICHYDRAULICS IN RELATION TOCUMMINS FUEL PUMPSPumps and the change from mechan-ical energy into pressureenergy -- volumetric outputpositive displacement -- non-positive displacement -- rotaryreciprocating -- propeller pumpsmixed flow pumps -- turbocharger



With Didactor

AM 1-12 PART I - MAINTAINING THEFUEL SYSTEM -- CUMMINSDIESEL ENGINES (part 2)A. Fuel flow characteristicsB. PTG fuel pumpPART II - UNIT INSTALLATION(ENGINE)A. Preparation for installationB. Installing engine

AM 1-13 PART I - MAINTAINING THEFUEL SYSTEM CUMMINSDIESEL ENGINES (part 3)A. More about the Cummins

fuel systemB. Calibrating the PT fuel

pumpC. Calibrating the fuel

injectorsPART II - RADIATOR SHUTTERSYSTEMA. Understanding the shutter

systemB. The shutterC. Shutter control cylinderD. Shutter control valveE. Air filters

AM 1-14 PART I - MAINTAINING THEAIR SYSTEM -- CUMMINSDIESEL ENGINESA. Definition of terms related

to the diesel air systemB. Principles of diesel air

compressorsC. Principles of air starting

motorsD. Servicing Cummins starting

motorsPART II - UNIT REMOVALTRANSMISSIONA. Preparation for removalB. Unit removal

PEINCIPLES OF TORCH CUTTINGChemistry and the torchdefinitions -- terms oxidationand the air -- oxyacetylenecutting -- carburizing flameneutral flame excess oxygenflame -- excess acetylene flame

OPERATION OF THE CUMMINSPT FUEL SYSTEM COMPONENTSPTG vs PTR -- fuel manifoldpressure -- engine torque --bypass holes -- folir strokes ofthe four cycle engine -- governoroperation at different speedscolors and governor springstrength -- aneroid control

UNDERSTANDING THE DIESELAIR SYSTEM.Valves and actuating gear in relationto flow of air and exhaust gases --valve timing -- function of the heatexchanger on turbochargedengines; altitudes and turbo-chargers -- naturally aspiratedengines -- extreme cold vs oxygencontent of air



With Didactor

AM 1-15 PART I - MAINTAINING THECOOLING SYSTEM -- CUMMINSDIESEL ENGINESA. Importance of the cooling

systemB. Cooling system componentsC. Evaluating cooling system

failuresD. Caring for the cooling

systemPART II - UNIT INSTALLATIONTRANSMISSIONA. Preparation for installationB. Installing transmission

AM 1-16 PART I - USE AND CARE OFSMALL HAND TOOLSA. Understanding torque and

how it is measuredB. Repairing and replacing

threaded fastenersPART II - PRINCIPLES OF THEPOWER DIVIDERA. Understanding the operating

principlesB. Power divider removal from

truck

AM 1-17 PART I - MAINTAINING THELUBRICATION SYSTEMCUMMINS DIESEL ENGINESA. Prolonging engine lifeB. Functions of the lubricating

systemC. Tracing the lubricant flowD. Determining lubrication

system failuresE. Maintaining lubrication

system componentsF. Learning about oil testsG. Field testing of oilPART II - UNIT INSTALLATIONAND REMOVAL -- DRIVE LINESA. Drive line descriptionB. Removal of drive lineC. Troubleshooting

PRINCIPLES OF DIESEL ENGINECOOLING SYSTEMSReview of GM and Cumminscooling systems -- pressurizedcooling radiator and the by-pass tube -- thermostats andvariations in temperatureWithnell radiators -- cold weatherand the cooling system -- pumpcavitation (implosion)

PRINCIPLES AND APPLICATIONSOF BASIC MACHINESBreaking down the complexmachine into smaller and simplermachines -- levers -- pulleyswheel and axle inclined planescrews and wedges -- terms (work,power and energy) -- horsepowerdefined mathematically -- mechanicaladvantage problems

UNDERSTANDING DIESELENGINE LUBRICATIONSYSTEMSCrankcase sludge, its content andwhere it is found in the enginecauses' of sludge -- low temperaturesludge -- high temperature sludge re-fuel soot -- blow-by -- theexpansion of aluminum heads andtemperature variations -- types ofoil filters



With Didactor

AM 1-18 PART I - UNDERSTANDINGENGINE GEARS AND GEAR-ING PRINCIPLESA. The purpose of engine

gearsB. Inspecting for gear

failuresC. Inspecting for shaft

failuresD. Using snap rings to

position gears orbearings

PART II - MACK IiTTER-AXLE POWER DIVIDERA. Operating principlesB. Repairing the Mack

power divider

AM 1-19 PART I - ENGINE TUNE-UPCUMMINS DIESEL ENGINESA. Pre tune-up checksB. Timing the engineC. Injector plunger and valve

adjustmentsD. Fuel pump adjustments on

the engine (PTR and PTG)PART II - FRONT ENDSUSPENSION AND AXLESA. History of front axlesB. Axle loads

AM 1-20 C UMMINS DIESEL ENGINEMAINTENANCE SUMMARYA. What engine break-in meansB. Engine break-inC. Torquing bearings (template

method)D. The need for maintenance

-6

UNDERSTANDING GEARS ANDGEAR RATIOSPrinciples of driver and drivengears -- shafts -- direction ofrotation - - idler gears -- gearratios -- gear speed -- speedratio -- types of gears keysand keyways

PRINCIPLES OF TUNE-UPCUMMINS DIESEL ENGINEFuel injection and top dead center(TDC) retarded/advancedearly injection and fuel knockpush rod adjustment -- camshaftgear adjustment -- valveadjustment -- fuel pump adjust-ment -- vacuum gauge readingsshims and the fuel pump

CUMMINS DIESEL ENGINEMAINTENANCE SUMMARYReview of diesel engine oilconsumption -- piston ringscylinder liner finishes -- contoursof mating surfaces -- engine break-in period -- template method oftorquing bearings -- safety pre-cautions

Automotive Maintenance Year I


With Didactor

AM 1-21 PART I - MAINTAINING THEAIR SYSTEM CATERPILLARDIESEL ENGINESA. Air induction and exhaust

systemB. Valve mechanismC. Troubleshooting the air

systemPART II - UNDERSTANDINGREAR END SUSPENSIONA. Purpose of Vehicle

suspensionB. Tandem drive axle

suspensionC. Compressed nitrogen

cylinder suspensionsystem

AM 1-22 PART I - MAINTAINING THEFUEL SYSTEM CATER-PILLAR DIESEL ENGINES(part 1)A. Fuel system comparisonsB. Fuel system supply com-

ponentsC. Fuel supply section main-

tenancePART II - UNDERSTANDINGTHE DIFFERENTIALA. Function of the differentialB. Construction of the

thifferentialC. Differential removal

AM 1-23 PART I - MAINTAINING THEFUEL SYSTEM -- CATERPILLARDIESEL ENGINES (part 2)A. Fuel injection sectionPART II - UNDERSTANDINGSTEERING SYSTEMSA. Description of the steering

system

MAINTAINING THE AIR INTAKEAND EXHAUST SYSTEMSCATERPILLAR DIESEL ENGINEComparison of CAT air system toGM and Cummins -- air pressureratio control regulator -- turbo-charger speed control hotexhaust from the poney engineafter-cooling -- air cleaners --valve rotors -- overhead cam-shafts priority valve

UNDERSTANDING THECATERPILLAR. FUEL SYSTEMMulti-cylinder type fuel pumppriming pump high pressurefuel lines -- fuel metered andpressurized -- inside the fuelpump -- rack limiter -- speedlimiter -- troubleshooting theCAT fuel system

UNDERSTANDING THECATERPILLAR FUEL SYSTEMMulti-cylinder type fuel pumppriming pump -- high pressurefuel lines -- fuel metered andpressurized -- inside the fuelpump -- rack limiter -- speedlimiter -- troubleshooting theCAT fuel system



With Didactor

AM 1-24 PART I - MAINTAINING THEFUEL SYSTEM --CATERPILLAR DIESELENGINES (part 3)A. Injection timing controlsB. GovernorC. Fuel system maintenance

tipsPART II - UNDERSTANDINGTHE VOLTAGE REGULATOR/ALTERNATORA. The charging systemB. Regulating the generator/

alternatorC. Charging system service

precautions

AM 1-25 PART I - CATERPILLARDIESEL ENGINE COOLINGSYSTEM D-8 AND 824MODELSA, Theory of the cooling

systemB. Cooling system componentsC. Maintenance tipsPART II - TIRES AND TIREHARDWAREA. General descriptionB. Liquid filled tiresC. Tire maintenanceD. Prolonging tire life

AM 1-26 PART I - CATERPILLARLUBRICATION SYSTEMS ANDCOMPONENTSA. The need for oilB. Service classification of

oilsC. Caterpillar lubrication

system componentsPART II - LEARNING ABOUTBRAKES (part 1)A, Principle of operation

(friction)B. Brake friction principleC. Brake control systemD. Inspection of brakes

UNDERSTANDING THECATERPILLAR FUEL SYSTEMMulti-cylinder type fuel pumppriming pump high pressurefuel lines -- fuel metered andpressurized -- inside the fuelpump -- rack limiter -- speedlimiter -- troubleshooting theCAT fuel system

CATERPILLAR DIESEL ENGINECOOLING SYSTEMReview of diesel engine coolingsystems -- radiationcirculation -- absorption -- scaledeposits and hot spots -- addingwater to hot engines -- trouble-shooting the cooling system

CATERPILLAR LUBRICATIONSYSTEMS AND COMPONENTSFunctions of oil in a dieselengine -- additives -- oil fluidityviscosimeter -- multiple viscosityranges Series a oils -- CAToil pump -- detergents in oil

I



With Didactor1./.,OAM 1-27 PART I - CATERPILLAR

STARTING (PONEY)ENGINE (part 1)A. General descriptionB. OperationC. Combustion space and valve

arrangement (startingengines)

PART II - LEARNING ABOUTBRAKES (part 2)A. Types of brakesB. Double actuated drum

. brakes

AM 1-28 PART I CATERPILLARSTARTING (PONEY)ENGINE (part 2)A. Starting engine

magneto (WICO)B. Magneto maintenanceC. Spark plugsPART II - UNDERSTANDINGMORE ABOUT STARTINGDEVICESA, General descriptionB. OperationC. LubricationD. Periodic checks and

adjustmentsE, Cranking motor drive

checks

AM 1-29 REVIEWING THE CON-STRUCTION OF ENGINECOMPONENTSA. Stationary partsB, Engine mo)ing partsC. Piston ringsD. Connecting rods and

piston pins

CATERPILLAR DIESELSTARTING ENGINEFunction of the CAT poneyengine -- starting mechanism(magneto) -- lubricationsystem -- exhaust manifoldand the diesel engine. --carburetor -- overrunningclutch -- spark plug science --combustion chamberdetonation -- electrical funda-mentals and the magneto

CATERPILLAR DIESELSTARTING ENGINEFunction of the CAT poneyengine -- starting mechanism(magneto) -- lubticationsystem -- exhaust manifoldand the diesel engine --carburetor overrunningclutch -- spark plug sciencecombustion chamber --detonation -- electrical funda-mentals and the magneto

NONE REQUIRED


1/1Text

Individualized InstructionWith Didactor

AM 1-30 PART I - CATERPILLARDIESEL ENGINE MAIN-TENANCE SUMMARYA. Troubleshooting the

engine on 988, 824 and834 CAT loaders anddozers

B. Troubleshooting theCaterpillar D8 engine

C. Troubleshooting theCaterpillar starting'engine

D. Removing the startingengine from a Caterpillar824 tractor

E. Troubleshooting theCaterpillar No. 12 motorgrader

PART II - REVIEWING FACTSABOUT ALTERNATORSA. Operation of the alternatorB. Alternator testing and

adjusting

SUMMARIZING CATERPILLARENGINESThis film lesson reviews theprevious nine units by askingquestions about their content.Troubleshooting questions aboutthe air, fuel, lubrication andcooling systems of the CATengine are restated and answeredwhere missed.

- 10 -

AUTOMOTIVE MAINTENANCE -- YEAR II


With Didactor

AM 2-1

AM 2-2

AM 2-3

UNDERSTANDING MECHAN-ICAL CLUTCHESA. Power from the engine

then what?B. Types of clutchesC. Component parts of the

clutchD. Clutch adjustment and

troubleshooting

MECHANICAL TRANS-MISSIONSA. Piirpose of trans-

missionsB. Ratio differenceC. Constant mesh trans-

missionD. Four-speed truck trans-

mission power flowE. Transmission trouble-

shooting

AUTOMATIC TRANS-MISSIONS -- HYDRAULICS(PART I)A. Why use hydraulicsB. Revie.wing basic physics

laws in relation tohydraulics

C. Understanding thehydraulic system

D. Developing a basichydraulic system

LEARNING ABOUT MECHAN-ICAL CLUTCHESPurpose of mechanical clutches --clutch construction -- engagementand disengagement -- hydraulicclutch operating principles --clutch adjustment and trouble-shooting clutch slippage --clutch noise -- torque -- foot-pound vs pound-foot -- lever

Astaprinciples as they apply to gearsand gearing -- gear ratios

UNDERSTANDING MECHAN-ICAL TRANSMISSIONSPurpose of transmissions --torque vs speed -- measuringtorque -- gear reductionprinciples -- mechanicaladvantage -- calculating mechanicaladvantage of gear, wheel andaxle arrangements -- changingspeed and direction with gears --magnifying force with gears --constant mesh transmissions

BASIC HYDRAULICSBasic laws of physics concerningpressure, work, power --liquid characteristics -- Pascal'sLaw -- mechanical advantage --kinetic energy and heat energy --laminar and turbulent flow --friction -- Bernoulli's principle

Automotive Maintenance -- Year II


With Didactor

AM 2-4

AM 2-5

AUTOMATIC TRANS-MISSIONS -- HYDRAULICS(PART XI)A. Reviewing facts about

pumpsB. Using valves for

controlC. Troubleshooting pro-

cedures on relief valvesD. Using directional control

valvesE. Flow control valves

AUTOMATIC TRANS-MISSIONS -- TORQUECONVERTERA. Fluid couplings (location

and purpose)B. Principle of operationC. Torque convertersD. Torqmatic converterE. Three stage, three element

torque converterF. Torque converter main-

tenance and troubleshooting

- 2

UNDERSTANDING DIRECTIONALCONTROL VALVESPurpose and uses of directionalcontrol valves -- directionalcontrol check valves pilotoperated check valves positionvalves -- spool valves -- manuallyoperated and pilot operated fourway valves -- pilot chokesshuttle valves -- electricallyoperated hydraulic circuitssolenoid controlled, pilotoperated valves -- rotary di-rectional valves -- troubleshootingdirectional valves -- effects ofdirt and heat -- back pressureinternal leakage detent valves

LEARNING ABOUT TORQUECONVERTERSConstruction and operation of fluidcouplings -- fluid flywheelcouplings -- construction andoperation of torque convertersfluid couplings vs torque con-verters converter oil flowpatterns -- kinetic energy -- rotaryflow and vortex flow -- two phaseconverter operation -- Torqmaticretarder (brake) maintenanceand troubleshooting maintenanceintervals -- oil changing -- con-verter stall -- causes of power loss



With Didactor

AM 2-6

AM 2-7

AM 2-8

AUTOMATIC TRANS-MISSIONS PLANETARYGEARINGA. Purpose of planetary

gearingB. Power transmission through

a planetary systemC. Hydramatic transmissionD. Hydraulic systemE. Gear failure and lubrication

AUTOMATIC TRANS-MISSIONS ALLISONTORQMATIC SERIES 5960AND 6060 (PART I)A. General specification dataB. Options for various

applicationsC. Road test instructionsD. Identification and

specification dataE. Allison TC -500 series

converterF. Converter hydraulic systemG. Maintaining the converter

AUTOMATIC TRANS-MISSIONS - ALLISONTORQMATIC SERIES 5960,6060 and 8860 (PART II)A. General descriptionB. Optional equipmentC. Transmission power flow

(splitter section)D. Transmission power flow

(range section)E. Inspection and maintenanceF. Troubleshooting the trans-

mission

UNDERSTANDING PLANETARYGEARING IN RELATION TOAUTOMATIC TRANSMISSIONSConstruction of planetary gearsystems -- sun rarplanetary pinions -- ring gearplanetary canDier -- obtainingminimum and maximum gearreduction wah planetary gearsminimum and maximum overdriveplanetary gearing L a hydra-matic transmission -- gear failureand lubViicatTI,on -- other causes ofgear failuro pitting -- metalfatigue normal wear

NO FILM REQUIRED

LEARNING ABOUT THE ALLISONTORQMATIC HYDRAULICSYSTEM (PART I)Driving combination oil pressure andscavenge pump -- oil filters --signal switch main pressurevalve -- lockup shitt valve inter-mediate range clutch trimmervalve -- fluid velocity (pitot)governor -- converter pressureregulator and 1%11(4 valve -- con-verter bypass valve -- converter-in check valve -- neutral e1 Paltrimmer valve


Text.... 41

Individualized InstructionWith Didactor

AM 2-9 AUTOMATIC TRANS-MISSIONS -- HYDRAULICSYSTEM (PART I)A. General descriptionB. Hydraulic circuitsC. Brake hydraulic circuit

and operation

AM 2-10 AUTOMATIC TRANS -MISSIONS -- HYDRAULICSYSTEM (PART II)A. Checking the hydraulic

systemB. Servicing the hydraulic

systemC, Examining the range control

valveD. Examining the lockup and

flow valveE. Examining the main regu-

lator valveF. Examining the brake valveG, Dual path transmission

principle

4

LEARNING ABOUT THE ALLISONTORQMATIC HYDRAULICSYSTEM (PART II)Neutral range hydraulic actionfirst range hydraulic action --second range hydraulic action --third range hydraulic actionfourth range hydraulic actionfifth range hydraulic actionsixth range hydraulic action --reverse range hydraulic actionlockup shift valve and clutchreview of basic operatingprinciples

1111NO

SUMMARIZING MECHANICALAND AUTOMATIC TRANS-MISSIONSReview of mechanical clutchoperating principles -- purposeof clutch -- mechanical clutchtroubleshooting -- clutch noise --review of mechanical and auto-matic transmission operatingprinciples -- idler gears -minimum and maximum gearreduction and overdrive -- reversereduction -- rev'!i,ew of fluidcouplings -- converter main-.tenance changing oil and filtersconverter stall -- loss of power



With Didactor

AM 2-11 INTRODUCTION TO ELEC-TRICAL MAINTENANCE FOROFF-HIGHWAY VEHICLESA. Fundamentals of elec-

tricity and magnetismB. Electromagnetic fieldsC. Magnetic force on a

conductorD. Electromagnetic

inductionE. Ohm's LawF, Meter movementsG. Glossary of terms

AM 2-12 LEARNING ABOUT BATTERYSERVICING AND TESTING(PART I)A. Battery components and

constructionChemical action inbatteriesThe battery and thecharging circuitBattery chargint voltageEffects of state of charge onbattery charging voltage andcharging ratesEffects of temperature onbattery charging voltage andcharging ratesTerminology

13.

C.

D.E.

F.

G.

5

UNDERSTANDING THE FUNDA-MENTALS OF ELECTRICITYAND MAGNETISMElements and compoundsatoms and moleculesprotons, electrons and neutronselectron movement conductorsand non-conductors -- amperage,voltage and resistance in relation toelectron flow -- principles ofmagnetism -- basic law ofmagnetism polarityprinciples of electromagnetismCurrent Theory vs ElectronTheory -- right hand ruleelectromagnetic fields -- electro-magnetic induction

0.6

AUTOMOTIVE BATTERIES IINTRODUCTION TO THE LEAD-ACID STORAGE BATTERYBasic functions of lead-acidstorage battery -- construction oflead-acid storage batteriesgrids and plates positive platesnegative plates -- plate groupscell packs development ofvoltage in lead-acid storagebatteries -- vent capselectrolyte -- specific gravity --changes in the battery platesduring charge and dischargegassing charging voltage vsCEMF and nth state of chargeand charging 'voltage temperatureand charging voltage and ratevoltage regulators



With Didactor

AM 2-13 BATTERY SERVICE ANDTESTING PROCEDURES(PART II)A. Electrolyte and specific

gravityB. Battery chargingC. Storage battery types

and designD. Battery capacity ratingsE. Battery installation9

servicing and testingF. Factors affecting battery

lifeG. Safety precautions

AM 2-14 UNDERSTANDING DCGENERATOR PRINCIPLES(PART I)A. What is a generator and

its use?B, Shunt generator principlesC. Power and ratings of a

generatorD. Armature reactionE. What is polarity?F. Two generator circuitsG. Application of generators

on the job

AUTOMOTIVE BATTERIES IIBATTERY SERVICING ANDTESTING PROCEDURESStoring lead-acid storagebattery wet charged batteriesvs dry charged batteriesself-discharge -- batteryinstallation and removaltest for proper battery instal-lation -- visual inspectioncondition and size of batterycables -- using hydrometer tomeasure electrolyte specificgravity -- hydrometer test inter-pretation -- electrolyte temperaturecorrection voltmeter testslight load test and interpretationbattery operation and performancein low temperature areas

01.1,1

DC GENERATORS IINTRODUCTION TO DC GENER-ATOR PRINCIPLESElectromagnetic inductionproducing current in a conductormoving through a stationary fieldconstruction and operation of DCgenerator -- speed of armaturerotation vs generator outputnumber of armature turns vsgenerator output strength ofthe field vs generator outputarmature reaction and brushpositioning -- mechanical neutraland load neutral positionsgenerator power and ratingsvoltage and current ratingseddy currents -- construction andoperation of voltage regulator andcurrent regulator identifying"A" circuit and "B" circuit systems



With Didactor

AM 2-15 UNDERSTANDING DCGENERATOR PRINCIPLES(PART II)A. Special generator circuitsB. Generator testingC. Generator polarity

and polarizing procedures

AM 2-16 LEARNING ABOUT ACGENERATOR (ALTERNATOR)PRINCIPLES (PART I)A. Reviewing electrical

fundamentalsB. Operating principles of

alternators

- 7 -

DC GENERATORS II --GENERATOR TESTINGPROCEDURESConstruction and operationof cutout relay -- cutoutrelay adjustment -- effect ofcurrent direction on twoadjacent coils -- identifying"A" and "B" circuits at thegenerator and at the regulator --four types of electrical mal-functions shorts, opens,grounds, high resistancetests for high resistancevisual inspection and trouble-shooting -- testing field circuitand armature for grounds, opens,shorts -- polarizing "A" circuitand "B" circuit generators

AC GENERATORS I UNDER-STANDING ALTERNATORPRINCIPLESElectromagnetic inductionproducing current in stationaryconductor by means of rotatingmagnetic field -- construction andoperation of AC generator(alternator) -- rotor, statorand rectifier assemblies -- pro-ducing AC n stator windingspositive diodes negative diodesand their functions -- current flowin the three phase stator assembly



With Didactor

AM 2-17 LEARNING ABOUT ACGENERATOR (ALTERNATOR)PRINCIPLES (PART II)A. Review of alternator

principlesB. Alternator servicing and

testingC. Alternator regulator

operating principlesD. Periodic regulator servicing

and general troubleshootingof the charging system

AM 2-18 ALTERNATOR ANDREGULATOR SERVICINGAND TESTING, AND ANINTRODUCTION TOTRANSISTOR REGULATORSA. Review of generator

principles, AC and DCB. Servicing and testing

alternatorsC. Introduction to transistor

regulators

AC GENERATORS IIREGULATOR AND FIELD RELAYOPERATING PRINCIPLES andALTERNATOR TESTINGConstruction and operation ofalternator regulator -- threeunit alternator regulators --construction and operation offield relay unit introductionto alternator testing -- abnormalbattery condition as a symptomof electrical system trouble --alternator field winding tests foropens, shorts, groundsstator winding tests for opensand grounds diode serviceprecautions -- diode testsusing low voltage test lamp orohmmeter

INTRODUCTION TO TRANSISTORSand TRANSISTOR CONTROLLED

AND TRANSISTORIZEDREGULATORSTransistor vs contact pointssemiconductors -- doping --N type and P type semiconductormaterials -- PN junctionforward and reverse biasconnections -- transistoroperation -- transistorizedregulators -- transistor con-trolled regulators -- usingtransistors to control alternatorfield current -- alternator outputtest -- regulator test's, for transis-torized and transistor controlledregulators

- 0.



With Didactor

AM 2-19 LEARNING ABOUT CRANK-ING MOTORSA. Cranking motorsB. Motor principlesC. Cranking motor circuitsD. Types of cranking motor

drivesE. Cranking motor solenoid

circuits

AM 2-20 TROUBLESHOOTING ELEC-TRICAL SYSTEMSA.

AM 2-21

B.

C.D.E.F.G.H.

Troubleshooting electricalsystems (introduction)Tools and instruments fortroubleshootingThe batteryPeriodic battery servicingThe DC charging systemPeriodic regulator servicingThe wiring circuitGeneral troubleshooting ofthe charging system

I. The AC charging systemJ. The cranking system (elec-

trical)K. General troubleshooting of

the cranking system

MICHIGAN /C LARK TRANS-MISSION -- COMPLETEPOWER TRAINA. Examining the power flowB. Unit oil flowC. Oil pressure in the con-

verter and transmissionsystem

9 S.

LEARNING ABOUT CRANK-ING MOTORSConstruction and operation ofcranking motors -- drivemechanisms -- electro-magnetism and cranking motorscranking motor solenoidcircuits -- Dyer drive crankingmotors troubleshooting andadjustment -- Bendix type drive

TROUBLESHOOTING ELEC-TRICAL SYSTEMS (INTRO-DUCTION TO BASIC ANDGENERAL PROCEDURES)"On-the-vehicle" inspection andservicing -- battery checks aspart of inspection and trouble-shooting -- using the voltmeterusing the ammeter using theohmmeter "A" and "B" circuitspolarizing generator servicing:armature and brushes regulatorserviding contact pointstroubleShooting the chargingsystem -- alternator chargingsystems -- troubleshooting thecranking system

UNDERSTANDING THEMICHIGAN/CLARK POWERTRAINConstruction and operation of thetorque converter lubricationof the converter and transmissionoil flow through the converter andtransmission system -- function ofthe transmission -- manual shiftcontrol valve -- maintaining thetransmission



With Didactor

AM 2-22 MICHIGAN/CLARK TRANS-MISSION CONVERTER/TRANSMISSIONA. A closer look at the con-

verterB. Converter assembly and

installationC. Transmission functionD. Transmission shifting

AM 2-23 MICHIGAN/CLARK TRANS-MISSION HYDRAULICSHIFTA. Mechanical and hydraulic

shiftingB. Oil flow through the con-

trol valve

AM 2-24 MICHIGAN/CLARK TRANS-MISSION -- OIL FLOWTHROUGH THE CONTROLCOVER ASSEMBLYA. Examining the control

cover assemblyB. Regulating Valve and

safety valveC. Inspecting the system

- 10 -

MICHIGAN /C LARK TRANS-MISSION - TRANSMISSIONAND CONVERTER FUNCTIONFunction of converter -- functionof transmission -- function ofgear box -- speed clutchesrange clutches -- directionclutches -- maintaining oil pres-sure in the converter/transmissionconverter stall -- function of oilcooler

MICHIGAN/CLARK TRANS-MISSION MECHANICAL ANDHYDRAULIC SHIFT And OILFLOW THROUGH THE VALVESAND CONTROL COVERASSEMBLYFunction of directional shift andspeed range levers -- function ofshift control valve -- oil flowthrough supply hoses, control valveand transmission control coveroil flow through supply hoses inthe various speed rangesfunction of accumulator, micro-switch, declutch valve anddirectional spool

MICHIGAN /CLARK TRANS-MISSION -- MECHANICAL ANDHYDRAULIC SHIFT And OILFLOW THROUGH THE VALVESAND CONTROL COVERASSEMBLYFunction of directional shift andspeed range levers -- function ofshift control valve -- oil flowthrough supply hoses, control valveand transmission control coveroil flow through supply hoses inthe various speed rangesfunction of accumulator, micro-switch, declutch valve anddirectional spool

I

r



With Didactor

AM 2-25 MICHIGAN/CLARK TRANS-MISSION -- TROUBLE-SHOOTINGA, Preliminary checicsB. Pressure and oil flow

checks,C. Troubleshooting tablesD. Troubleshooting vehicles

under field conditionsE. Analyzing unacceptable

inspection results

MICHIGAN/CLARK TRANS-MISSION -- TROUBLESHOOTINGThe components as parti, of asystem -- mechanical andhydraulic checks as part of atroubleshooting procedureintroduction to pressure and flowrate checks -- hydraulic checksat converter7in9 converter-out,charging pump -- transmissionclutch pressure and leakagechecks -- lube flow and converterleakage checks -- review ofcheck points for hydraulic checks

reportr e sumes - eric · reportr e sumes. ed 021 119. vt 006 006. automotive diesel maintenance....

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