CONSTRUCTION EQUIPMENT MECHANIC TRAINING COURSE MANUAL

Install System, Equipment and Component Grounds Manual (43 Pages)

Lesson 1: Install Grounding Electrodes
Practice Exercise
Answer Key and Feedback

Lesson 2: Install Circuit Grounds
 

Practice Exercise
Answer Key and Feedback

Appendix A: Metric Conversion Chart

Appendix B: List of Common Acronyms

Lesson 1: Brake-System Principles
Practice Exercise
Answer Key and Feedback

Lesson 2: Hydraulic Brake Systems
Part A - Principles
Part B - Troubleshooting
Practice Exercise
Answer Key and Feedback

Lesson 3: Compressed-Air Brake Systems
Part A - Principles and Basic Components
Part B - Troubleshooting
Practice Exercise
Answer Key and Feedback
 

Lesson 4: Air-Over-Hydraulic Brake Systems
Part A - Construction and Operation
Part B - Troubleshooting
Practice Exercise
Answer Key and Feedback

Lesson 5: D7G Brake System
Part A - Operation
Part B Troubleshooting
Practice Exercise
Answer Key and Feedback

Appendix A: Metric Conversion Chart

Appendix B: List of Common Acronyms

Overview
Administrative Instructions
Grading and Certification Instructions

Lesson 1: Hydraulic Pumps
Part A: Positive -Displacement Pumps
Part B: Gear Pump
Part C: Vane Pump
Part D: Piston Pump
Practice Exercise
Answer Key and Feedback

Lesson 2: Hydraulic Valves
 

Part A: Pressure-Control Valves
Part B: Directional-Control Valves
Part C Control-Valve Repair
Practice Exercise
Answer Key and Feedback
Examination

Appendix A: List of Common Acronyms

Appendix B: Recommended Reading List

Appendix C: Metric Conversion Chart

Appendix D: Publication Extracts

Lesson 1: Establishing an Account and Acquiring
Materials Through the Army Publications System
Part A: The Standard Army Publications System
Part B: Publications-Account Management
Practice Exercise
Answer Key and Feedback

Lesson 2: Maintaining a Technical Reference Library
 

Part A: Posting Changes
Part B: Filing Publications
Practice Exercise
Answer Key and Feedback

Appendix A: List of Common Acronyms

Appendix B: Recommended Reading List

Lesson 1: Clutch and Brake Steering System
Learning Event 1: Fundamentals of a Clutch and Brake Steering System
Learning Event 2: Troubleshoot a Clutch and Brake Steering System
Learning Event 3: Replace a Steering Brake
Review Exercise
Review Exercise Solutions
 

Lesson 2: Power Steering System
Learning Event 1: Fundamentals of a Power Steering System
Learning Event 2: Troubleshoot a Power Steering System
Learning Event 3: Replace a Steering Control Valve
Review Exercise
Review Exercise Solutions

Lesson 1: Micrometers
Learning Event 1: Identify Types and Mechanics of Micrometers
Learning Event 2: Measure Using the Micrometer
Practice Exercise
Practice Exercise Solutions

Lesson 2: Calipers and Dividers
Learning Event 1: Identify Various Types of Calipers and Dividers
Learning Event 2: Measure Using Calipers and Dividers
Practice Exercise
Practice Exercise Solutions

Lesson 3: Dial Indicators
Learning Event 1: Identify Dial Indicators by Type and Construction
Learning Event 2: Measure Using Dial Indicators
Practice Exercise
 

Practice Exercise Solutions

Lesson 4: Measuring Gages
Learning Event: Identify Types and Uses of Measuring Gages
Practice Exercise
Practice Exercise Solutions

Lesson 5: Torque Wrenches
Learning Event: Identify Torque Wrenches by Types and Use
Practice Exercise
Practice Exercise Solutions

Lesson 6: Hydraulic Filler/Bleeder
Learning Event: Using the Hydraulic Filler/Bleeder
Practice Exercise
Practice Exercise Solutions

Lesson 1: Employment of Earthmoving Equipment
Overview
Introduction
Part A - Identify Types and Characteristics of Tractors
Part B - Describe Dozer Blades and Techniques to Increase Dozer Production
Part C - Calculate the Production Rates for Dozers
Part D - Describe Characteristics of Scrapers and Techniques for Maximum Output
Part E - Tractor/Scraper Production
Part F - Describe Grader Characteristics and Techniques to Increase Grader Production
Part G - Calc ulate Production Rates for Grader
Practice Exercise
Answer Key and Feedback

Lesson 2: Employment Compacting and Ditching Equipment
Overview
Introduction
Part A - Describe Soil Preparation Equipment and Its Capabilities
Part B - Describe Compaction Equipment and Techniques to Increase Production
 

Part C - Estimate Production Rates on Compaction Equipment
Practice Exercise
Answer Key and Feedback

Lesson 3: Employment of Lifting Loading, and Hauling Equipment
Overview
Introduction
Part A - Describe Cranes and Techniques to Increase Production
Part B - Select a Crane for a Specific Project
Part C - Calculate Production Rates for Cranes
Part D - Describe Other Lifting, Loading, and Hauling Equipment
Part E - Hauling Equipment
Part F - Air Compressors and Pneumatic Tools
Practice Exercise
Answer Key and Feedback

Appendix A: List of Common Acronyms

Appendix B: List of Symbols

Lesson 1: Multiple Pump Fuel Systems
Learning Event 1: System Components and Operation
Learning Event 2: Troubleshooting the Multiple Pump Fuel System
Learning Event 3: Component Adjustment, Repair, or Replacement
Review Exercise
Review Exercise Solutions

Lesson 2: Unit Injector Fuel Systems
Learning Event 1: System Components and Operation
Learning Event 2: Troubleshooting the Unit Injector Fuel System
Learning Event 3: Component Adjustment, Repair, or Replacement
Review Exercise
Review Exercise Solutions

Lesson 3: Roosa Master Distributor Fuel Systems
Learning Event 1: System Components and Operation
Learning Event 2: Troubleshooting the Roosa Master Fuel System
Learning Event 3: Component Adjustment, Repair, or Replacement
 

Review Exercise
Review Exercise Solutions

Lesson 4: Pressure-timed Fuel Systems
Learning Event 1: System Components and Operation
Learning Event 2: Troubleshooting the Pressure-Timed Fuel System
Learning Event 3: Component Adjustment, Repair, or Replacement
Review Exercise
Review Exercise Solutions

Lesson 5: Fuel Supply Units
Learning Event 1: Fuel Supply Pumps
Learning Event 2: Governors
Learning Event 3: Fuel Filters
Learning Event 4: Timing Devices
Learning Event 5: Cold Weather Starting Aids
Review Exercise
Review Exercise Solutions

Lesson 1: Fundamentals of Maintenance Supervision
Learning Event 1: The Army Maintenance System
Learning Event 2: Maintenance Supervision Responsibilities
Learning Event 3: Maintenance Supervision
Learning Event 4: Standing Operating Procedure
Review Exercise
Review Exercise Solutions

Lesson 2: Fundamentals of Maintenance Operations
Learning Event 1: Workload Organization
Learning Event 2: Inspections
Learning Event 3: Army Oil Analysis Program
Review Exercise
Review Exercise Solutions
 

Lesson 3: Tactical and Garrison Maintenance Sites
Learning Event 1: Tactical Maintenance Sites
Learning Event 2: Garrison Maintenance Sites
Review Exercise
Review Exercise Solutions

Lesson 4: Fundamentals of Supply Operations
Learning Event 1: Supply Procedures and Terminology
Learning Event 2: Prescribed Load List, Requesting Supplies, Supply Status, Cancellation, Turn-In Procedures
Learning Event 3: Inventories, Toolroom Control, Hand Receipts
Learning Event 4: Accountability and Responsibility, Handling of Damaged Property, Report of Survey
Review Exercise
Review Exercise Solutions

Chapter 3: MOS/Skill Level Tasks, Skill Level 1

Subject Area 1: Preventive 1
Perform a Weekly Service on an Item of Construction Equipment
Perform a Monthly Service on an Item of Construction Equipment
Perform a Quarterly Service on an Item of Construction Equipment
Perform a Semiannual Service on an Item of Construction Equipment
Perform an Annual Service on an Item of Construction Equipment
Perform a Biannual Service on an Item of Construction Equipment
Perform a Usage Service on an Item of Construction Equipment
Sample an Item of Construction Equipment Enrolled in the Army Oil Analysis Program

Subject Area 2: Electrical 1
Repair a Wiring Harness on an Item of Construction Equipment
Replace Batteries on an Item of Construction Equipment
Replace a Starter on an Item of Construction Equipment
Replace a Switch on an Item of Construction Equipment
Replace an Alternator on an Item of Construction Equipment
Replace an Electrical Gauge on an Item of Construction Equipment

Subject Area 3: Engines 1
Replace a Fuel Tank on an Item of Construction Equipment
Replace a Fuel Line on an Item of Construction Equipment
Replace a Fuel Filter on an Item of Construction Equipment
Replace a Fuel Pump on an Item of Construction Equipment
Replace an Injector Pump on an Item of Construction Equipment
Replace a Hand Primer Pump on an Item of Construction Equipment
Replace Air Filters on an Item of Construction Equipment
Replace a Turbocharger on an Item of Construction Equipment
Replace an Oil Filter on an Item of Construction Equipment
Replace an Oil Line on an Item of Construction Equipment
Replace a Water Pump on an Item of Construction Equipment
Replace a Thermostat on an Item of Construction Equipment
Replace an Engine Oil Cooler on an Item of Construction Equipment
Replace Drive Belts on an Item of Construction Equipment
Replace an Engine Cooling Fan on an Item of Construction Equipment
Replace a Radiator on an Item of Construction Equipment
Replace a Water Hose on an item of Construction Equipment

Subject Area 4: Hydraulics 1
Repair a Hydraulic Accumulator on an Item of Construction Equipment
Replace a Hydraulic Line on an Item of Construction Equipment
Replace a Hydraulic Pump on an Item of Construction Equipment
Replace a Hydraulic Control Valve on an Item of Construction Equipment
Replace a Hydraulic Relief Valve on an Item of Construction Equipment
Replace a Hydraulic Cylinder on an Item of Construction Equipment
Replace Hydraulic Filters on an Item of Construction Equipment
Replace an Accumulator on an Item of Construction Equipment
Repair a Hydraulic Cylinder on an Item of Construction Equipment

Subject Area 5: Power Trains 1
Replace a Transmission on an Item of Construction Equipment
Replace a Driveshaft on an Item of Construction Equipment
Replace Universal Joints on an Item of Construction Equipment
Replace a Power Divider on an Item of Construction Equipment
Replace a Hydrojet on an Item of Powered Bridging Equipment
Replace a Differential on an Item of Construction Equipment
Replace a Final Drive on an Item of Construction Equipment
Repair a Winch Brake on an Item of Construction Equipment
Repair Steering Brakes and Clutches on an Item of Construction Equipment
Repair a Clutch Assembly on an Item of Construction Equipment
Replace a Steering Gear on an Item of Construction Equipment

Subject Area 6: Brakes 1
Adjust the Brake Shoes on an Item of Construction Equipment
Replace a Master Cylinder on an Item of Construction Equipment
Replace a Brake Booster on an Item of Construction Equipment
Replace a Treadle Valve on an Item of Construction Equipment
Replace a Brake Air Compressor on an Item of Construction Equipment
Replace a Slack Adjuster on an Item of Construction Equipment
Replace a Brake Cylinder on an Item of Construction Equipment
Replace the Brake Lines on an Item of Construction Equipment
Replace the Brake Shoes on an Item of Construction Equipment
Replace the Brake Pads on an Item of Construction Equipment
Replace the Brake Drums on an Item of Construction Equipment
Replace the Brake Rotors on an Item of Construction Equipment
Replace a Moisture Separator on an Item of Construction Equipment
Replace an Air Pressure Gauge on an Item of Construction Equipment
Repair a Brake Air Compressor on an Item of Construction Equipment
Repair a Brake Caliper on an Item of Construction Equipment
Replace an Air Brake Safety Valve on an Item of Construction Equipment
Repair an Air Brake Safety Valve on an Item of Construction Equipment
Replace a Brake Chamber on an Item of Construction Equipment

Subject Area 7: Suspension Systems 1
Replace a Track on an Item of Construction Equipment
Repair a Track Assembly on an Item of Construction Equipment
Replace a Wheel and Tire on an Item of Construction Equipment
Replace a Drive Sprocket on an Item of Construction Equipment
Replace an Idler Wheel on an Item of Construction Equipment
Replace Shock Absorbers on an Item of Construction Equipment

Subject Area 8: Body, Cab, Hull and Accessories 1
Replace a Cutting Edge on an Item of Construction Equipment
Replace a Ripper Tooth on an Item of Construction Equipment
Replace a Winch Cable on an Item of Construction Equipment
Replace a Winch on an Item of Construction Equipment

Chapter 3: MOS/Skill Level Tasks, Skill Level 2

Subject Area 1: Preventive 2
Perform a Quality Assurance/Control Inspection on an Item of Construction Equipment
Perform Battle Damage Assessment and Repair (BDAR) on an Item of Construction Equipment

Subject Area 2: Electrical 2
Replace a Wiring Harness on an Item of Construction Equipment
Replace an Electronic Sensor on an Item of Construction Equipment
Replace an electronic-control module on an item of construction equipment
Troubleshoot a Starting System on an Item of Construction Equipment
Troubleshoot a Charging System on an Item of Construction Equipment
Troubleshoot an Accessory Circuit on an Item of Construction Equipment

Subject Area 3: Engines 2
Replace an Oil Pump on an Item of Construction Equipment
Replace a Fuel Injector on an Item of Construction Equipment
 

Replace a Blower on an Item of Construction Equipment
Replace an Engine on an Item of Construction Equipment
Repair an Engine on an Item of Construction Equipment
Troubleshoot a Fuel System on an Item of Construction Equipment
Troubleshoot a Lubrication System on an Item of Construction Equipment
Troubleshoot a Cooling System on an Item of Construction Equipment
Troubleshoot an Air Induction System on an Item of Construction Equipment

Subject Area 4: Hydraulics 2
Fabricate a Hydraulic Line on an Item of Construction Equipment
Repair a Hydraulic Relief Valve on an Item of Construction Equipment
Repair a Hydraulic Pump on an Item of Construction Equipment
Repair a Hydraulic Control Valve on an Item of Construction Equipment
Troubleshoot a Primary Hydraulic System on an Item of Construction Equipment
Troubleshoot a Hydraulic Suspension System on an Item of Construction Equipment
Troubleshoot a Hydraulic Drive System on a Item of Construction Equipment
Troubleshoot a Hydraulic Steering System on an Item of Construction Equipment

Subject Area 5: Power Trains 2
Replace a Torque Converter on an Item of Construction Equipment
Replace a Planetary Drive on an Item of Construction Equipment
Repair a Transmission on an Item of Construction Equipment
Repair a Differential on an Item of Construction Equipment
Repair a Final Drive on an Item of Construction Equipment
Repair a Power Divider on an Item of Construction Equipment
Repair a Hydrojet on an Item of Construction Equipment
Repair a Steering System on an Item of Construction Equipment
Troubleshoot a Transmission on an Item of Construction Equipment
Troubleshoot a Transmission on an Item of Construction Equipment
Troubleshoot a Final Drive on an Item of Construction Equipment
Troubleshoot a Power Divider on an Item of Construction Equipment
Troubleshoot a Planetary Drive on an Item of Construction Equipment
Troubleshoot a Hydrojet on an Item of Powered Bridging Equipment

Subject Area 6: Brakes 2
Repair a Brake Master Cylinder on an Item of Construction Equipment
Repair a Brake Booster on an Item of Construction Equipment
Troubleshoot an Air Brake System on an Item of Construction Equipment
Troubleshoot an Air-Over-Hydraulic Brake System on an Item of Construction Equipment

Chapter 3: MOS/Skill Level Tasks, Skill Level 3

Subject Area 1: Preventive 3
Perform an Initial Inspection on an Item of Construction Equipment
Perform an In-Process Inspection on an Item of Construction Equipment
Perform a Final Inspection on an Item of Construction Equipment

Subject Area 2: Electrical 3
Determine the Cause of an Electrical-Component Malfunction on an Item of Construction Equipment

Subject Area 3: Engines 3
Determine the Cause of an Engine Component Failure on an Item of Construction Equipment

Subject Area 4: Hydraulics 3
Determine the Cause of a Hydraulic Component Failure on an Item of Construction Equipment

Subject Area 5: Power Trains 3
Determine the Cause of a Power Train Component Malfunction on an Item of Construction Equipment

Subject Area 6: Brakes 3
Determine the Cause of a Brake Component Failure on an Item of Construction Equipment

Subject Area 7: Common Logistic Tasks 3
Manage a Shop Safety Program
Maintain a Publications Library
Establish Maintenance Facilities
Assist in Preparing a Standing Operating Procedure
Manage Tool Control Procedures
Manage Key Control Procedures
Manage the TMDE Calibration Program
Recon Terrain/Route
Supervise Maintenance Operations
Interpret Maintenance Operational Overlay
Deploy Maintenance Support Teams
Manage the Standard Army Maintenance System (SAMS)
Manage the Unit Level Logistics System (ULLS)
Manage the Unit Army Oil Analysis Program (AOAP
Deploy Company Maintenance Team/Recovery Support Team
Review the Army Materiel Status System (AMSS) Reports
Perform Senior Rater Responsibilities for a Maintenance Section
Supervise Platoon/Section Administrative Procedures
Manage Combat Stress
Ensure Maintenance Operations are in Compliance With the Army Environmental Program
Enforce Compliance With the Shop Safety Program
Coordinate Support for the Maintenance Platoon/Section
Select a Field Maintenance Site
Prepare an Operational Overlay for Maintenance Operations
Control Flow of Work Through the Maintenance Shop
Integrate Automated Logistics Support Systems
Plan Logistics Support for Maintenance Operations
Monitor the Preparation and Disposition of the Army Materiel Status System (AMSS) Reports
Analyze the Prescribed Load List (PLL) Report
Monitor Quality Control Program
Analyze Bench Stock Listing
Analyze Open Work Request Reconciliation Listing
Analyze Completed Shop Workload Summary
Analyze Shop Deadline and Deferred Workload Listing
Analyze Shop Workload Summary Listing
Maintain Property Accountability
Prepare Standing Operating Procedures for Maintenance Operations
Supervise the Deployment of Company Maintenance Team/Recovery Support Team/Maintenance Support Team
Conduct a Route Reconnaissance for a Maintenance Mission
Conduct an Area Reconnaissance for a Maintenance Mission
Manage Battlefield Maintenance Support
Perform Support Operations NCO Duties
Manage Maintenance Operations at a Maintenance Collection Point
Provide Maintenance Support During Tactical Operations
Supervise Preventive Maintenance Checks and Services (PMCS)

Chapter 1: Introduction

Chapter 2: Trainer's Guide
General
Subject Area Codes
Critical Tasks List

Overview

Chapter 1: Toolrooms and Tools

Chapter 2: Layout and Benchwork

Chapter 3: Metals and Plastics

Chapter 4: Power Saws and Drilling Machines

Chapter 5: Offhand Grinding of Tools and Selection of Carbide Tools

Chapter 6: Engine Lathes

Chapter 7: Milling Machines and Milling Operations

Chapter 8: Vertical Turret Lathe and Horizontal Boring Mill
 

Chapter 9: Shapers, Planers, and Engravers

Chapter 10: Precision Grinding Machines

Chapter 11: Computer Numerical Control Machines

Chapter 12: Metal Buildup

Chapter 13: Repair Work

Chapter 14: Gears and Gear Cutting

Chapter 15: Metallurgy and Heat Treating

Glossary

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