Construction Mechanic Advanced - Construction methods and practices
Duties And Responsibilities Of Supervisory Personnel
Maintenance And Repair Foreman
Preventive Maintenance
Records And Reports
Preservation, Storage, And Depreservation Of Vehicles And Equipment
Techniques Of Scheduling
Figure 1-4.Sample Format For Specification For Scheduled Maintenance Inspections And Services.
Progress Control And Shop Workload
Figure 1-6.Order For Supplies Or Services, Dd Form 1155.
Contract Maintenance And Repairs
Figure 1-7.Quality Deficiency Report, Sf 368.
Figure 1-8.Report Of Excess Personal Property, Sf 120.
Technical Assistance
Chapter 2 Alfa Company Shops Supervisor
Heat, Light, And Ventilations
The Maintenance Supervisor
Shop Inspectors
Electrical Shop
Cost-Control Supervisor
Batallion Maintenance Program
Organizational Maintenance
Figure 2-4.Equipment Repair Order Log Sheet.
Depot Maintenance
Figure 2-7.Pm Schedule.
Figure 2-9.Direct Turnover (Dto) Log.
Equipment Repair Order And Continuation Sheet
Repair Parts
Cosal Support
Figure 2-14.Single-Line Item Release/Receipt Document, Dd Form 1348-1.
Technical Library
Wrong Parts!
Batallion Equipment Evaluation Program (Beep)
Figure 2-17.Equipment Evaluation Inspection Guide.
Figure 2-18.Equipment Evaluation Inspection Guidecontinued.
Figure 2-19.Attachment Evaluation Inspection Guide.
Comcbpac/Comcblant Responsibilities
Embarkation
Storage
Defense Reulitilization And Marketing Office (Drmo)
Chapter 3 Engine Troubleshooting And Overhaul
Brake Horsepower
Graphs And Diagrams
Timing Diagrams
Figure 3-5.Relationship Between Torque And Horsepower.
Two-Stroke-Cycle Engine Timing
Figure 3-7.Timing Diagram Of A Two-Stroke-Cycle Diesel Engine.
Figure 3-8.-Power Strokes In One-, Four-, Six-, And Eight-Cylinder Engines.
Multiple-Cylinder Engines, Continued
Engine Troubleshooting
Engine Testing
Vacuum Gauge Test
Cylinder Leakage Test
Tachometer
Valves, Valve Mechanisms, And Cylinder Heads Servicing
Valves In Block
Valve Removal
Valve Guide Servicing
Figure 3-22.Valve Contact Correction.
Valve Seat Insert Replacement
Crankshaft Servicing
Crankshaft Journal Check
Crankshaft Installation
Cylinder Servicing
Cylinder Liners Replacement
Piston And Rings Servicing
Piston Pins Fitting
Operational Testing
Chapter 4 Troubleshooting Electrical Systems
Rectifiers
Figure 44.-Typical Wiring Diagram (Transistor Regulator).
Troubleshooting The Charging System With A Voltampere Tester
Alternator Test
Excessive Output Test
Charging System Insulated Circuit Resistant Test
Charging System Ground Circuit Resistance Test
Troubleshooting The Alternator Using The Engine Analyzer Screen
Charging Circuit Diodes
Troubleshooting The System Using The Battery Starter Test
Cranking Voltage Test
Starter Insulated Circuit Resistance Test
Starter Ground Circuit Resistance Test
Solenoid Switch Circuit Resistance Test
Transistor Ignition System
Capacitor Discharge Ignition System
Electronic Lean Burn System/Electronic Spark Control
Unit Ignition System
Computerized Ignition System
Distributorless Ignition System
Troubleshooting
Transisitor Ignition System
Table 4-1.-Troubleshooting Chrysler Electronic Ignition
Troubleshooting Lighitng Systems And Electrical Accessories
Headlights
Fuses And Circuit Breakers
Directional Signals
References
Chapter 5 Fuel System Overhaul
Reassembly And Adjustment
Gasoline Fuel Injection Systems
Figure 5-1.-Mechanical-Timed Injection.
Figure 5-2.-Electronic-Timed Injection.
Continuous Fuel Injection Systems
Servicing And Precautions
Diesel Fuel Injection Systems
Troubleshooting
Compact Fuel System
Figure 5-11.-Precombustion Chamber And Fuel Injection Valve.
Sleeve Metering Fuel System
Roosa Master Fuel Injection Pump
Table 5-1.-Troubleshooting Chart For Roosa Master Fuel System
Figure 5-16.-Gauge Installed For Checking Transfer Pump Pressure.
American Bosch Fuel Injection Pump
Figure 5-19.-Metering And Distributing Fuel Pump Assemblyleft Sectional View.
Figure 5-21.-Fuel Intake Flow Diagram.
Troubleshooting
Table 5-2.-Troubleshooting Bosch System
Nozzle Operation
Troubleshooting
Valve Opening/Pressure Test
High-Pressure Test
Injector Disassembly, Cleaning And Inspecting, And Reassembly
Cummins Pressure Time Fuel Injection System
Pump Cleaning And Inspection
Pump Reassembly
Injector Maintenance And Testing
Air Induction System
Blower Removal And Disassembly
Superchargers
Turbochargers
Removal, Disassembly, And Cleaning
Cold Starting Devices
Figure 5-40.-Typical Diesel Engine Glow Plug.
Ether
Chapter 6 Inspecting And Troubleshooting Brake Systems
Figure 6-3.-Using A Drum Micrometer To Measure The Drum.
Brakes Drag
Table 6-1.-Troubleshooting Chart For Hydraulic Brakes (Standard)
Table 6-1.Troubleshooting Chart For Hydraulic Brakes (Standard)Continued
Table 6-1.Troubleshooting Chart For Hydraulic Brakes (Standard)Continued
Table 6-1.Troubleshooting Chart For Hydraulic Brakes (Standard)-Continued
Table 6-1.Troubleshooting Chart For Hydraulic Brakes (Standard)Continued
Car Pulls To One Side
Troubleshooting Vacuum-Assisted Hydraulic Brakes (Power) Systems
Table 6-2.Troubleshootiug Chart For Vacuum-Assisted Hydraulic Brakes (Power)
Hydroboost Troubleshooting
Troubleshooting Air Brake Systems
Figure 6-11.Air Reservoir With Air Drain Cock.
Table 6-3. Air Brake System Troubleshooting Chart
Air-Over-Hydraulic
Parking/Emergency Brakes
Figure 6-14.Automotive Type Emergency/Parking Brake Axle Mounted.
Antilock Brakes
References
Chapter 7 Clutches And Automatic Transmissions
Figure 7-2.Friction Disk Clutch With Flexible Center.
Figure 7-4.Clutch Operation.
Figure 7-7.Hydraulic Clutch Operating System.
Clutch Malfunctions
Slipping
Clutch Pedal Pulsation
Table 7-1.Clutch Assembly Troubleshooting Chart
Turbo Hydra-Matic Model 400
Planetary Gears
Coupling ((Torque Converter Operation)
Figure 7-15.Torque Converter, Partial Cutaway View.
Figure 7-16.Torque Converter In Fluid Coupling Stage.
Hydraulic System Operation
Figure 7-21.Internal Gear Type Of Pump Assembly.
Preventive Maintenance
Linkage And Band Adjustment
Refilling The Transmission
Transmission Overhaul
Table 7-2.-Turbo Hydra-Matic Model 400 Troubleshooting List
Table 7-2.Turbo Hydra-Matic Model 400 Troublesbooting Listcontiued
Figure 7-26.Removing The Control Valve Assembly.
Figure 7-32.Removing The Pump Assembly.
Figure 7-37.Removing The Center Support Snap Ring.
References
Chapter 8 Air Compressor Overhaul
Types Of Air Compressors
Reciprocating Compressor
Screw Type Of Compressor
Components Of Compressors
Pressure Control System
Air Intake System
Figure 8-12.Cleaning An Air Filter With Low Pressure Air.
The Air Receiver
Intercoolers
Lubrication System
Figure 8-19.-Rotary Vane Air Compressor Lubrication System.
Table 8-1.-Air Compressor Troubleshooting Chart
Air Compressor Troubleshooting
Figure 8-20.-Removing Vanes For Inspection And Replacement.
References
The Public Works Shop Inspector
Acceptance Inspections
Figure 9-3.-Dod Property Record Card, Dd Form 1342 (Front).
The Batallion Maintenance Shop Inspector
Embarkation Inspections
Preservation Inspections
Deadline Inspections
Figure 9-7.-Crane Condition Inspection Record.
Figure 9-7.-Crane Condition Inspection Record Continued.
Final Inspections
Pascal'S Law
Components
Rotary Pumps
Figure 10-4.-Lobe Type Of Pump.
Vane Pump
Reciprocating Pumps
Variable Volume Piston Pump
Hand Pumps
Actuators
Figure 10-13.-Example Of Piston Type Of Cylinder.
Motors
Figure 10-15.-Typical Vane Type Of Hydraulic Motor.
Valves
Pressure Regulator Valves
Selector Valves
Check Valves
Reservoirs
Accumulators
Application
Filters
Micronic Filter
Filter Classifications
Figure 10-31.-Full-Flow, Porous Metal, Bypass Electrical-Indicating Hydraulic Filter.
Hydraulic Systems
Types Of Hydraulic Systems
Hydrauoic System Troubleshooting And Maintenance
Troubleshooting
Maintenance
Hydraulic System Contamination
Control Of Contamination
Figure 10-37.One Example Of A Hydraulic Liquid Contamination Test Kit.
Flushing The System
References
Chapter 11 Troubleshooting Transmissions, Transfer Cases, And Differentials
Troubleshooting Transmissions
Table 11-1.Troubleshooting Transmissions (5-Ton Military)
Inspecting The Transmission
Figure 11-5.Transmission Gears And Shafts-Exploded View.
Testing Transmission For Malfunctions
Testing Transmission For Malfunctions, Continued
Overhaul Of The Transmission
Troubleshooting Transfer Cases
Figure 11-10.Transfer Case To The Transmission.
Table 11-2.Transfer Case Troubleshooting Chart
Figure 11-13.Transfer Shafts, Bearing, And Gearsexploded Viewlegend.
Figure 11-14.Front Axle Engagement Air Control Diagramlegend.
Troubleshotting The Power Takeoff
Troubleshooting The Differential
Figure 11-17.Typical Differential And Axle Assembly With Ring And Pinion.
Figure 11-19.No Spin Differential-Exploded View.
Axles, Wheels And Tracks
Full-Floating Axles
Service And Maintenance
References
Chapter 12 Wheel And Track Alignment
Figure 12-2.Caster Angle.
Figure 12-3.Kingpin Inclination.
Figure 12-6.Difference Of Radii Between Inner And Outer Wheels.
Adjusting Wheel Alignment
Alignment Procedures
Figure 12-11.Mechanical Toe-Measuring Gauge.
Figure 12-14.Ball Joint Wear Indication.
Figure 12-16.Various Locations Of Caster-Camber Adjustment Points.
Caster/Camber Adjustments
Toe-In And Steering Wheel Adjustment
Nonadjustable Angles
Track Alignment
Track Roller Frame Alignment With Sprocket
References
Chapter 13 Air-Conditioning Systems
Figure 13-1.The Closed Circuit Refrigeration Cycle.
Figure 13-2.Warming The Refrigerant By Using Hot Water.
Refrigeration Cycle
Components Of The Air-Conditioning System
Expansion Valve
The Evaporator
Thermostatic Switch
Figure 13-9.Suction Throttling Valve.
The Compressor
Figure 13-11.Compressor Components.
Figure 13-12.Compressor Superheat Switch.
Figure 13-13.Two-Cylinder Reciprocating Compressor.
Figure 13-14.Four-Cylinder Radial Compressor.
Four-Cylinder Radial Compressor
Malfunctions Of Components In The Air-Conditioning System
Inspecting The Air-Conditioning System For Leaks
Propane Torch Detector
Purging The Air-Conditioning System
Adding Refrigerant To The Air-Conditioning System
Functional Testing Of The Air-Conditioning System
Other Refrigerants
References, Continued