heavy equipment1

8/12/2019 Heavy Equipment1

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Department of Mechanical Technology Heavy Equipment

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Mechanical Technology Department

Heavy Equipment


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Department Mechanical Technology Major Heavy Equipment

Program Description:

This program has been designed to meet the training needs of the local labor market by taking

into considerations the National Occupational Skill Standards (NOSS) for heavy equipment

"technician" Trade. The training in this program includes general skills in English Language,

Mathematics, Physics, as well as Human Communication Skills. Also, the program includes

training on basic skills related to heavy equipment systems and components and their operation,

and the fundamentals of heavy equipment electrical and electronic systems that would help the

trainee in his career. In addition, the program provides specialized skills in the field of heavy

equipment mechanics related to maintenance and repair techniques of heavy equipment

mechanical components and systems after performing set of technical tests on the heavy

equipment. The training on how to set diagnostic strategies for the mechanical faults in heavyequipment would also be given.

In Technical Colleges, training on heavy equipment Technology is performed through

(1742) contact hours, in addition to (420) hours of cooperative-training in the labor market

through cooperation between the colleges and industrial establishments, governmental and

private sectors (like heavy equipment dealers) that work fully or partially in heavy equipment

sector.

The graduate of this program is awarded an associate degree certificate, and expected to work

as a technician in civil and military establishments linked to heavy equipment.

General Objective:

This program aims at providing the trainee with hands on skills, experience and necessaryinformation required to exercise work as a technician in the field of heavy equipment.

Detailed Objectives:

By the end of this program the trainee will be able to efficiently perform the following:

1) Follow up safety procedures and instructions on heavy equipment workshops before

commencement of any job.

2) Recognize basic heavy equipment systems and components, functions and methods of

operation.

3) Use different specialized tools in heavy equipment field to perform necessary tests on

heavy equipment systems and components.4) Use maintenance and service manuals of different heavy equipment models and deal with

heavy equipment spare parts.

5) Execute maintenance and repair operations on heavy equipment systems and components

with related skills of assembly and disassembly.

6) Set up diagnostic strategies for the mechanical faults in heavy equipment systems and

components.

7) Recognize technical terms in the field of heavy equipment mechanics.

8) Deal with new emerging technologies in different heavy equipment systems.


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Mechanical Technology Department

Heavy Equipment Section

Study Plan Distributed over all Trimesters

No. of UnitsNo

Course

Code Course Title Pre-requisite C.U. L W T C.H.1 101ISLM Islamic Culture -1 J J J 2 2 0 0 2

2

COMP 101 Introduction to

Computer

Applications

J J J

2 0 4

0

4

3

ENG 103 General English J J J

4 4 0 2 6

4 ARAB 101 Arabic Language J J J 2 2 0 0 2

5 PHY 115 General Physics J J J 3 3 1 4

6 113MATH General Mathematics J J J 4 4 0 0 4

7VOC 107 Vocational Guidance

and Excellence J J J

2 2 00

2

FirstTrim

ester

Sum

19 17 4 3 24

No. of UnitsNo

Course

Code Course Title Pre-requisite C.U. L W T C.H.1 164MEV Engineering Drawing J J J 2 4 4

2162HEQ Preparatory

Workshops J J J

2 4

4

3 163HEQ Hydraulic Basics J J J 4 2 4 6

4164ENG Technical English -1 ENG

103

4 4 2 6

5

161 HEQ Vocational Safety at

Heavy-Duty

Workshop

1 2

2

6116MATH Specialized

Mathematics

113

Math

3 3 1 4

SecondTrimester

Sum 16 9 14 3 26


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No. of Units

NoCourse

Code Course Title Pre-requisite C.U.

L W T C.H.1

ISLM 102 Islamic Culture -2 ISLM

101

2 2 2

2PHY 116 Specialized Physics 115

PHY

2 2 2 4

3HEQ 171 Hydraulic and

Pneumatic Systems

HEQ

163

3 1 4 5

4

HEQ 172 Diesel Engines HEQ

162

4 2 4

6

5HEQ 173 Power

Transmission

HEQ

162

4 2 4

6

6174HEQ Heavy Equipment

Electricity

HEQ

162

4 2 4 6

ThirdTrimester

Sum 19 11 16 2 29

No. of UnitsNo

Course

Code Course Title Pre-requisite C.U. L W T C.H.1

HEQ 251 Diesel Engine Fuel

Systems

HEQ

172

3 1 4

5

2HEQ 252 Heavy Duty Brake

System

HEQ

162

5 3 4

7

3HEQ 253 Heavy Equipment

Control Systems

HEQ

171

4 2 4

6

4ENG 264 Technical English -

2

ENG

164

4 4

26

5HEQ 254 Technical Drawing 164

MEV

2 4

4

Fou

rthTrimester

Sum 18 10 16 2 28


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C.U. Credit Hours

L : Lecture

W : Workshop

T: Practice

C.H. Contact Hours

No. of UnitsNo

Course

CodeCourse Title

Pre-

requisite C.U. L W T C.H.

1

MGT

101

Professional Ethics and

Communication Skills

J J J 2 2 2

2HEQ

261

Hydraulic and Pneumatic

System maintenance

HEQ

171

4 2 4

6

3HEQ

262

Traction Systems HEQ

173

4 2 4

6

4HEQ

263

Heavy Equipment Maintenance

&Troubleshooting

HEQ

162

4 2 4

6

5

HEQ

264

Suspension and Steering

Systems

HEQ

162

5 3 4

7

FifthTrimester

Sum 19 11 16 27

Units NoNo

Course

Code Course Title Pre-requisite C.U. L W T C.H.Sixth

Trimester

1 HEQ 299 Cooperative TrainingAll

Courses4 At least 420 hours

Units No

C.U. L W T C.H.Total Programs Unites

95 58 66 10 134

Total Programs Contact Hours (1742 + 420) 2162


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Department Mechanical Technology Major Engines and Vehicles

Course name Engineering Drawing Code 164MEV

Prerequisite None

Course description:

This course includes training in the basics of

engineering drawing, the method of using

drawing tools, orthographic projection,

conversions, symbols, sections and hatching.The course highlights methods of representing

details of mechanical parts through

engineering drawing by orthographic

projection and sections. Identification of

drawing symbols and terms are also included.

Trimester 1 2 3 4 5

Credit hours 2

L -

W 4Contact

hoursT -

General course objectives:

The course aims at providing the trainees with the ability to use engineering drawing to readdrawings and understand symbols, it also prepare the trainees to correctly employ the basics and

symbols of engineering drawing in representing details of mechanical parts.

Detailed ObjectivesRequired Performance

Specifications

Related

Tasks

First: Procedural Objectives:

The trainees should be able to:

1)

Explain the meaning of different lines

used in engineering drawing.

-

Explanation of the meaning of

different lines used in

engineering drawing

2) Identify different symbols used to transfer

information.

- Identification of different

symbols used to transfer

information

3) Read and understand engineering

drawing and printed sheets.

- Read engineering drawing and

printed sheets

B6, E1,

E8,

E10,

E11,

E12,

G13,

H1, H2,

I1, I14,

I17, K7,

K10


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4)

Analyze drawing and write technicalreports.

-

Analysis of drawing andwriting of technical reports.

Second: Auxiliary Objectives (Cognitive and

Behavioral):


1) Identify different types of drawing tools

used in engineering drawing.

- Identification of the types of

drawing tools used in

engineering drawing.

2) Read some visual means and 3D

AutoCAD computer drawings.

- Ability to differentiate

between the types of

projections in engineering

drawing.

3) Identify some sections of automotive

parts.

- Comparison of authentic

sectioned parts of automotive

components with their

technical drawings.

B6, E1,

E8,

E10,

E11,

E12,

G13,

H1, H2,

I1, I14,

I17, K7,

K10

Safety Requirements:

Compliance with safety instructions found in the engineering drawing hall.

Subjects (Theoretical and Practical) Related Tasks

Principles of engineering drawing - Determine type of transmission

Orthographic projection - Check differential gears

Symbols and terms - Check drive axles

Sections and their types- Check propeller shaft support

bearings

- Check universal joints

E1,

E8,E10,

E11,

E12,

H2

- Check springs


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- Check fly wheel and replace the

clutch

Detailed Practical Course

Hours Content Evaluation Tools

8

Principles of engineering drawing:

- Engineering drawing as a language for technicians

- Tools and equipment used

-

Types of lines- Methods of writing figures and numbers

- Projection methods

- Distribution of drawing sheet

- Freehand drawing

- Scale of drawing (enlargement / reduction)

12

Orthographic projection:

-

Orthographic projection of points, lines and areas- Orthographic projection of the first angle

- Projection symbols

- Different view projections of bodies

- Hidden details

- Applications

8

Dimensions:

-

Introduction- Dimensions techniques

- Reference and dimension lines

- Arrow line drawing

- Methods of writing dimensions

- Writing dimensions on circles (diameters and radii)

- Applications

Direct observation

(practical performance)Oral questions

Written questions


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12

Isometric drawing:

- Methods of isometric representation

- Representation of circling surfaces and holes

- Applications

12

Sections and sectioned shapes:

- The need for sections

-

Section levels

- Full section and half section

- Broken out, revolved, removed, and partial section

- Applications

References:

1- James H, "Drafting, technology", Earle Addison-Wesley

Publications Co.

2-

M.A.Parker & L.J. Dennis, "Engineering drawing Fundamentals',Stanley Theories.

3- 3- Warren J. Luzadder, "Fundamentals of Engineering Drawing',

Prentice-Hall, 1986, Ninth Edition.


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Heavy EquipmentMajorMechanical TechnologyDepartment

HEQ 162CodePreparatory WorkshopsCourse Title

Prerequisites

54321Trimester

2Credit Hours

(Hour/week)

L

4W

T

Contact

Hours

(Hour/week)

Course Description:

In this course the trainees are introduced to the

fundamentals of preparatory workshops and

engineering measuring, as well as the fundamentals of

safety procedures. The trainees are also introduced in

this course to the tools and equipment used in the

workshop, heavy equipment parts which include; the

engine, power train systems, under carriage, driving

shafts, differential, suspension and steering, different

brake systems and their types and parts

General Goal:

This course aims to introduce the trainees to the fundamentals of preparatory workshops and

engineering measuring, as well as the fundamentals of safety procedures. The trainees are also

introduced in this course to the tools and equipment used in the workshop and all heavy

equipment parts.

Behavioral Objectives:


Understand the fundamentals of preparatory workshops and engineering measuring.

Be familiar with the basic safety procedures.

Identify the tools and equipment used in the workshop.

Be familiar with heavy equipment parts which include different power train systems,

suspension and steering, different Brake systems and their types and parts.


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Topics

The fundamentals of preparatory workshops and engineering measurement

Safety procedures Tools and equipment used in the workshop

Heavy equipment parts which include; different power train systems, suspension and

steering systems, different brake systems and their types and parts

References:


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Detailed Curriculum (Practice)

Behavioral ObjectivesContentsHrs


apply safety rules

carry out measuring methods

carry out manual cutting

methods using different tools

Basic skills which include:

safety rules

measuring methods

manual cutting methods using

different tools

4

carry out metal forming by

filing, bending, cutting and forming.

Metal forming which includes: filing

bending

cutting

forming

4

carry out methods of joining metals;

which include

joints classifications

joints riveting joints welding

Methods of joining metals; which

include:

joints classification

joint riveting joint welding

4

basic knowledge of operating machines;

which include:

types of tools and equipment

operating equipment

Machine and tool operation

basics; which include:

types of tools and equipment

operating equipment

4


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knowledge of workshop

industrial safety procedures;

which include:

precaution methods

methods for storing flammable

materials

methods of arranging equipment

for emergencies

Workshop industrial safety

procedures:

precaution methods

methods for storing flammable materials

methods of arranging equipment for

emergencies

4

knowledge of correctly using

tools, machines and

equipment in the workshop

knowing how to protect oneself

from injuries when using workshop

tools, machines and equipment

protecting tools, machines and

equipment from any harm

Tools, machines and equipment

used in the workshop

all types of filing tools with different

smoothing levels

all forging tools in all shapes and sizes

wrenches and pullers in all shapes and

sizes

heavy machinery (turning machines for

valves, discs, drums . etc)

4


Understand basic information to do

with heavy vehicles

Compare between wheeled and

crawler equipments.

Heavy equipment types.

Dumpers.

Tractor Scrapers

Wheel dozers

Backhoes

Compactors

Wheeled loader

Fork lift

Graders.

Wheeled tractors.

4


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identify the cooling system and its

main parts

identify the lubricating system in

the engine and its main parts

identify the fuel system and its

main parts

identify the ignition system and its

main parts identify the electric circuits in the

car

The engine, its components and

parts; which include:

cooling system

lubricating system

fuel system

ignition system

electric circuits

8

Identify power train parts,

their types and components;

which include:

friction clutch and its different

types

hydraulic coupling

torque converter

different types of propeller shafts,

connections and bearings

back axel unit, its components and

importance

axels and rods

Power train parts, their types

and components; which include:

friction clutch and its different types

hydraulic coupling

torque converter

automatic gear boxes

different types of propeller shafts,

connections and bearings

back axel unit, its components and

importance

axels and rods

2

Identify Steering and

suspension, their types and

components; which include:

springs, shock absorbers etc

control arms, rods, dust boots, ball

bearing , etc

wheel alignment angles , their types

and importance

Steering and suspension, their

types and components; which

include:

springs, shock absorbers etc

control arms, rods, dust boots, ball

bearings, etc

wheel alignment angles, their types and

importance

2


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Identify the brakes, their

types and components; which

include:

hydraulic brakes (drum and disc

brakes)

air brakes (air reservoir, valves,

etc)

booster, levers, linkages, parking

brakes and engine brakes

Brakes, their types and

components; which include:

hydraulic brakes (drum and disc brakes)

air brakes (air reservoir, valves, etc)

booster, levers, linkages, parking brakes

and engine brakes

4

Identify under carriage components;

which include:

Crawler track

Sprocket wheel

Idler wheel

Track rollers

Track tension adjuster system

Track heavy equipment:

Under carriage

Crawler track

Sprocket wheel

Idler wheel

Track rollers

Track tension adjuster system

4

The trainees should be able to know the

difference between single and tandem

wheels.

Wheeled heavy equipment:

Single wheels

Tandem wheels

4


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Department Mechanical Technology Major Heavy Equipment

Course name Vocational Safety atHeavy-Duty Workshop

Code 161 HEQ

Prerequisite None

Course description:

Vocational Safety at Heavy-Duty Workshops

is an important part of the workplace that

trainees should be familiar with. This course

covers how to wear work clothes, safety gear,choosing and preparing the appropriate

workplace, methods of using tools and

equipment and their safety, methods of using

lifts. The workshop safety section covers the

proper methods for getting rid of exhaust

gases, proper storing of flammable materials

and using fire extinguishers.

Trimester 1 2 3 4 5

Credit hours 1

L -

W 2

Contact

hours

(hour/week)T -


The course aims to introduce the trainees to Vocational Safety at Heavy-Duty Workshop which is

an important part of any workplace. The trainees learn to wear work clothes, safety gear, choosing

the proper location for working and preparing it for that, methods of using tools, equipment, their

safety, and methods of using lifts. The trainees also learn workshop safety procedures, and proper

storing of flammable materials and using fire extinguishers.

Skill Objectives:


Know which work clothes and safety gear are most suitable.

Know how to choose a suitable location for working and how to prepare it for that.

Know how to correctly use tools and operate equipment and their safety, and methods of using

lifts.

Follow safety procedures inside the workshop (properly get rid of exhaust gases).

Properly store flammable materials and use fire extinguishers.


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Subjects (theoretical and practical):

Method of wearing work clothes and safety gear

Method of choosing a suitable location for working and preparing it for that Method of using and operating tools, equipment and their safety, and methods of using lifts

Following safety procedures in the workshop (properly get rid of exhaust gases)

Method of storing flammable materials and using fire extinguishers


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Hours Content Skill Objectives Relatedtasks

4

1 Clothes:

- wearing work clothes

- ensure that the clothes are

free of any metal parts

- wear safety goggles

- wear gloves


- Choose the correct work

clothes and safety gear for

safety, as well as the safety

of the car and for the

general appearance of the

mechanic.

A1

2

2 The place:

- choosing a proper location

for the job

- placing the car in the right

location for the job

- ensure that the floor is free

of any liquids spills

- ensure the presence of safety

equipment

- Prepare a suitable place for

working on the car.

- Ensure that the floor is free

of any liquid spills.

- Ensure the presence of

safety equipment.

A2

4

3 Using tools:

- Knowing the tools and using

the most suitable ones for the

job

- Taking care of the tools

- Ensuring the safety of the

vehicle

- Use tools properly to avoid

injuries, safe usage and

storage of tools.

A3

4

4 Equipment:

- Proper usage of equipment

- Using the right device

- Taking care of the equipment

- Use equipment properly to

avoid injuries, safe usage and

storage of equipment.

A4


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Heavy EquipmentMajorMechanical TechnologyDepartmentHEQ163CodeHydraulic BasicsCourse Title

Prerequisites

54321Trimester

4Credit Hours

(Hour/week)

2L

4W

T

Contact

Hours

(Hour/week)

Course Description:

This course includes the study of Pascal's law,

Bernoulli principle, force and pressure transmission in

hydraulic systems and determining the type of flow

with solving some exercises. Also, the course includesthe principle properties of compressed air, dealing

with the unit used, as well as an introduction to the

special devices that convert energy and the devices

used in energy control.

General Goal:

The general goal is the study of physical properties of pneumatic and hydraulic systems,

and to study the basic laws of hydraulic systems.



Understand the physical properties of hydraulic systems and basic laws of hydrostatics and

hydrodynamics.

Understand the properties of the hydraulic oils and determine their specifications.

Performing the calculation of the pressure loss in the pipes.

Be familiar the theory of operation and the structure and know the symbols of pumps,cylinders, hydraulic motors and the directional control valves and the control valves of

pressure and flow rate.

Understand the basic properties of compressed air as medium used in energy transmission

for the purposes of control, and the other necessary specific properties of compressed air.

Understand the principles that should be awarded in preparing compressed air, the devices

that are used in pneumatic energy conversion, and also the control devices used in

pneumatic energy.


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Theoretical and Practical Topics:-

Definitions: hydraulics hydrostatics hydrodynamics Hydrostatics

Pressure force transmission in hydraulic systems Pascal's law

Fluid flow kinematics

Flow types continuity equation Bernoulli equation

Pressure drop

Oils properties and types

Viscosity- properties classifications testing Symbols of hydraulic components

Energy conversion devices (pumps hydraulic drive station)

Cylinders and hydraulic motors

The physical properties of compressed air

The method of preparing compressed air

Symbols of hydraulic and pneumatic components

Fluid mechanics and its applications Robert Dogerty Mc-Graw-Hill

company.

The first training book Manzman and Roxroth.References:


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Detailed Curriculum (Theory)

Related

TasksBehavioral ObjectivesContentsHrs

B13

B14The trainees should be able to:

Be familiar with fluid mechanics-

fluid statics (hydrostatics)- fluid

dynamics (hydrodynamics).

Illustrate the definition of the

hydraulics and hydraulic systems,

and also the fields of usage for

hydraulic systems.

Identify the physical quantities

and special units in hydraulics.

Be familiar with the states of

matter (solid-liquid-gas)

specific gravity density and its

relationship to temperature

specific weight specific volume

compressible and

incompressible fluids idealfluid- viscosity viscosity

coefficient absolute viscosity

and kinematic viscosity and their

units).

Definitions(hydraulics

hydrostatics hydrodynamics):

Special units in hydraulics

Hydrostatics

Hydrodynamics

Fluids

Viscosity

2


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B4B9

H3

H4


Define pressure absolutepressure gauge pressure

atmospheric pressure the

international and practical units

of pressure.

Express the pressure resulting

from external forces (Pascal's

law).

Understand how the pressure can

be increased in hydraulicsystems.

Describe the forces of

transmission in hydraulic system-

hydraulic pistons pressure

converter.

Express pressure in terms of the

fluid height.

Solve problems to do with:

pressure calculations and force,

and pressure transmissions in

hydraulic systems.

Hydrostatics pressure:

Pressure definitionPascal's law

Force transmission in

hydraulic system

Exercises

4


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B2

B3

B5

C7


Describe the types of flow:laminar and turbulent, and know

the factors affecting the flow type

calculation of Reynolds number

in circular pipes solving

exercises to determine the type of

flow continuity equation and

solving its application problems .

Understand the kinetic energy to

the flowing fluid and how tocalculate it calculation of

potential and pressure energy.

Deduce the energy equation for

steady incompressible fluid flow

(Bernoulli principle) solving

applied problems in calculating

the flow rate, force, piston speed,

the time taken in advance, and

return strokes of the piston

determining the relationship

between the flow rate, the cross

section area and pressure drop

determine the work and power of

the hydraulic systems

Calculations of designing a

simple hydraulic circuit used for

raising a certain weight through a

certain distance by a certain

speed; including the power andcapacity of the pump and the tank

size the types of valves.

Fluid kinematics Fluid flow:

Flow typesReynolds number

Continuity equation

Equation of motion

Bernoulliprinciple

4


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B5H3

H4


Calculate the pressure drop insimple pipes for the compressible

(gases vapors) and

incompressible fluids (liquids).

Calculate the pressure loss and

flow rate in pipes calculations

of pressure loss using the

relationship between the flow

velocities, type of flow according

to the approximate formulae. Determine the pressure loss using

charts.

Pressure drop:

Calculations of pressure lossin pipes

Calculation of loss and flow in

pipes

2


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D9

B13

B14


Identify the functions ofhydraulic oils and the quality

requirements for hydraulic oils.

Identify the characteristics of

hydraulic oil and the viscosity

effect on the leakage and friction

describe the viscosity

expression be familiar with the

different expressions of viscosity

absolute and kinematicviscosity and international and

practical units of viscosity

understand the method of

measuring viscosity understand

the concept of viscosity index

understand the effect of

temperature and pressure on

viscosity be familiar with the

type of hydraulic oils make a

suitable hydraulic oil selection

after evaluating its different

properties (viscosity-

incompressibility-foam damping

ability to separate water and air

release- oxidizing resistance

durability - freezing point flash

point boiling point suitability

with the hoses.

Be familiar with theincombustible hydraulic liquids

and their different groups.

Know of maintenance

instructions, storage and

resistance of hydraulic oils

analysis and explaining the

meaning of valves symbols,

cylinders, and different

accessories according thestandards 1219 DIN/ISO.

Types and properties of

hydraulic oils:

Functions of the hydraulic oils

Hydraulic oils characteristics

Different expression of

viscosity

Symbols of hydraulic

elements

6


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J9J10


Understand the physicalquantities and the special units

of the compressed air volume

and pressure laws- atmospheric

pressure and its measuring units

absolute pressure gauge

pressure the physical

properties and air laws the

relationship between pressure

volume and temperature ingases solve some applied

exercises using the laws taught

previously, and convert to the

international units SI.

Physical properties of air:

Special unit for compressedair

Volume and pressure laws

Air laws

Relation between the pressure-

volume temperature in gases

Solving a number of applied

exercises

4


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J1

J2

J3

J5

J9

J10


Understand the concepts ofabsolute humidity maximum

relative humidity degree of

saturation determine the air

humidity in terms of

temperature- solve exercises to

calculate condensed water

types of flows : laminar and

turbulent the mutual effect

between the flow rate andpressure advantages of using

air as a working fluid

describing the methods of air

drying knowledge of installing

compressed air tanks and water

traps and air pipes the

principles required in the

installation process.

Use charts to calculate pipe

diameter knowledge of using

the charts in calculating the

equivalent length for the flow

resistance through valves and

fittings and how to modify the

pipe calculations using charts

to determine flow rate

knowledge of the pressure filter

performance water separator

and oiling device and theirsymbols.

Preparation of compressed air:

Humidity conceptUsing compressed air as a

working medium

4


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Related

TasksBehavioral ObjectivesContentsHrs

B13

B14The trainees should be able to:

Identify the viscosity of the types

of liquids.

Viscosity Measurements:

6

B3

B9

H3H4


Apply the laws of hydrostatics.

Measuring the hydraulic

pressure through the height of

the measured liquid

8

B2

B3

B5

C7


Describe the flow types: laminar

and turbulent and knowledge the

factors on the types of flow

calculating the Reynolds number

in circular ducts.

Reynolds process

14

B5

H3

H4


Measure the pressure loss for

compressible and incompressible

fluids.

Measure the flow losses.

Measure the pressure and flow

rate losses in pipes.

Measuring the pressure loss

and flow rate in the pipes

24


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HEQ174CodeHeavy Equipment ElectricityCourse Title

HEQ162Prerequisites

54321Trimester

4Credit Hours

(Hour/week)

2L

4W

T

Contact

Hours

(Hour/week)

Course Description:

The first part of the course covers batteries, alternators

and starting motors. The second part covers the lights,

windshield wipers and horns.

The course focuses on the new elements introduced in

the above mentioned systems and circuits for heavy

equipments. The practical part of the course includes

many tests as well as disassembly and assembly

procedures for those systems and circuits

General Goal:

The course is designed to give the trainees the required knowledge of electrical systems

and circuits. Also, it enables them to deal practically with heavy equipment electricity.



Identify different components of electrical systems as well as how they work and affect

each other.

Understand how to choose the appropriate element for a certain vehicle (i.e. battery,

starting motor, etc)

Be familiar with to check, remove and install different elements.


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Topics

Basic electrical & electronic components

Batteries

Charging systems

Starting systems

Lights

Windshield wipers

Horns

Diesel Equipment,Vol.I, E.,J., Schulz

McGraw-Hill book Company, New York, U.S.A. 1982

Heavy Duty Truck Systems , I., Norman, R., Scharff,

J., Corinchock, Delmar Publishers, Albany, N.Y., U.S.A..1992

Modern Farm Power, W., J., Promersberger, D.,W.,

Priebe , F., E., Bishop, Reston Publishing Company&

A Prentice-Hall Company, Reston, Virginia, U.S.A.. 1979

References:


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Distinguish between electrical and

electronic elements and know their

functions

1-Basic electrical/electronic components:

Brief review about (switches, relays,

fuses, circuit breakers, solenoids, diodes

and transistors).

2

Identify battery components and

types.

Differentiate between battery

charging and discharging, as well

as how to choose a battery.

2-Batteries:

Battery duty, elements and

classifications

Charging and discharging of a battery

Battery ratings

4

Identify charging systems

components and circuits.

Identify alternator components

Identify how an alternator produces

electricity and how a regulator

regulates its output

2-Charging systems:

Charging systems components and

circuits

Alternator components and operation

Regulators components and operation

6

Choose the appropriate starting

motor for a particular heavy vehicle

Determine the type of any starting

system and its features

4-Starting systems:

Electrical starting systems (starting

motor requirements, components and

operation)

Hydraulic starting systems

Pneumatic starting systems

4


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Be familiar with light components

and circuits

Be aware of light importance fordriving safety

5-Lights:

Headlights and taillights systems Turn-signal and emergency lights

Stoplights and backup lights

4

Understand how they work6-Windshield wipers:

Components, circuits and operation4

Understand how they work7-Horns: Components, circuits and operation

2


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Enable the trainees to:

Identify if a component is defective

or not (through different tests).

1-Basic electrical/ electronic components:

Checking, testing and substituting

electrical and electronic components.

2

Learn how to test a battery in a safe

way and charge it, in addition to

jump starting a heavy-duty vehicle.

2-Batteries:

Application of safety measures

Performing battery tests and charging as

well as jump starting (case of a 24v

system).

6

Determine charging system

elements and be able to

disassemble and assemble

alternator components.

Check and test charging systems.

3-Charging systems:

Completing alternator tests (output test,

field current test, etc)

Performing alternator disassembly and

assembly

Applying necessary modifications to

produce 24v output.

14

Check, test, disassemble and

assemble electrical starting systems

as well as hydraulic and pneumatic

starting systems.

4-Starting systems;

Checking and testing electrical starting

systems (no-lead test, cranking current

test, etc)

Carrying out disassembly and assembly

operations of starting motors Testing hydraulic and pneumatic starting

systems as well as removing and

mounting of their important elements

8


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Determine different lights.

Identify removal and installation

steps.

5-Lights:

Performing checks and tests concerning

different lights Removing and installing different lights

as well as their adjustment

10

Perform windshield wiper tests and

other related services.

6-Windshield wipers:

Carrying out relevant checks and tests,

as well as disassembly and assembly

steps

6

To inspect, test and service horns.7-Horns:

Checking and testing horn components

Removing and installing horns

6


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HEQ172CodeDiesel EnginesCourse Title

HEQ162Prerequisites

54321Trimester

4Credit Hours

(Hour/week)

2L

4W

T

Contact

Hours

(Hour/week)

Course Description:

This course is designed to provide the trainees

with both a theoretical and practical background in the

basic operating principals of diesel engines, fuels, and

classifications. Practical experience in overhauling,

testing, troubleshooting, and tuning of diesel engines.

Disassembly, inspection of parts, reassembly,

maintenance procedures, and running a diesel engine

will also be covered. Auxiliary systems such as

lubrication, cooling, intake and exhaust, turbocharger,

and blowers will be emphasized.

General Goal:

The trainees acquire basic knowledge of diesel engines operating theories , parts,

classifications, and auxiliary systems. Plus the practical experience in inspecting, faultdiagnosing, repair, adjusting, and overhauling diesel engines.



Explain the fundamentals of diesel engines operating theories, parts, and classifications.

Explain cooling, lubrication, and auxiliary systems: such as intake, exhaust systems

components and operating theories.

Explain heavy duty brake system components as found in heavy equipment.

Inspect, repair, and adjust diesel engine systems.

Overhaul diesel engines.


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Topics

Diesel engines fundamentals

Four stroke and two stroke cycles

Diesel engines classifications

Diesel fuel characteristics

Cooling, lubrication, intake, and exhaust systems

Inspection, repair, and adjustment of engine systems

Fault diagnosing, testing, and overhauling diesel engines

Diesel Engine and Fuel Systems, Barry Wellington and Alan

Asmus

Diesel and Mobile Plant Technology, Clifford M. TempestReferences:


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Explain diesel engine

constructional parts and four and

two-stroke cycles.

Distinguish between different types

of diesel engines.

Define the characteristics of diesel

fuels.

1-Diesel engine fundamentals:

Engine construction

Four stroke and two stroke cycles

Diesel engine classifications

Diesel fuel characteristics

2

Explain the stages of combustion in

a compression ignition engine and

determine different types of

combustion chambers.

Explain the phenomena of 'diesel

knock', as well as the causes and

factors affecting its occurrence.

Explain the purpose and operation

of glow plugs.

2-Combustion in compression ignition

engines:

The stages of combustion

Combustion chambers (open combustion

chambers, pre-combustion chambers and

swirl chambers)

Diesel knock

Cold starting aids (glow plugs: layout

and operation)

4

Recognize cylinder head

components and the method of

inspection.

3-Cylinder head and attachments:

Intake and exhaust valves (valve seats-

valve guides-injector sleeves)

Methods of cylinder head and valve

service

2


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Recognize cylinder block parts andexplain different types of cylinder

liners and methods of inspection.

4-Cylinder blocks:

Types of cylinder blocks (air cooled andwater cooled cylinder blocks)

Cylinder liners (dry and wet liners)

Cylinder liner wear and measurements

Cylinder block service

2


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Explain crankshaft assembly and

methods of performing balancing

Explain the function of a flywheel.

4-Crankshafts:

Crankshaft assembly

Crankshaft bearings-crankshaft oil seals

The flywheel

Crankshaft balancing

2

Define different types of pistons

and connecting rods and their

related attachments.

5-Pistons, rings, and connecting

rods:

Types of pistons-piston cooling

Piston pin

Piston rings and types

Connecting rods

2

Explain valve train components and

methods of inspection and timing

the valves.

6-Valve timing mechanism:

Valve timing

Valve train components

Camshaft camshaft drives

Valve train service

2


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Differentiate between air and watercooled systems.

Explain components and operations

of air cooled and water cooled

systems.

6-Cooling systems:

The importance of cooling Types of cooling system (water and air

cooled systems)

Cooling system components and

operations (radiator-cap-coolant-

thermostat-water pump-the fan-

transmission oil cooler)

2




Explain the importance of the

lubrication system in diesel

engines, and determine types and

components of different systems.

7-Lubrication systems:

Types of engine lubricating systems

Lubrication systems components and

operations (oil pumps-oil filters-oil

coolers)

Diesel lubricating oils

2

Explain the components of air

intake and exhaust systems, and

recognize their faults.

Indicate the effect of supercharging

on diesel engine performance.

Explain turbocharger construction

and operation, and its effect on

engine power, fuel consumption,

and exhaust emissions.

8-Air and exhaust systems:

Air intake system in diesel engines

Air cleaners (types-construction)

Turbochargers (construction and

operation)

Blowers

Air intake troubles

Exhaust system

Mufflers (types and operation)

2


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Diagnose, inspect faults, performtesting, and necessary

measurements, and explain the

steps of diesel engine overhauling.

9-Diesel engine faultfinding, testing

and overhauling:

Faultfinding (compression testing-diesel

exhaust smoke)

Diesel engine testing (purpose of

testing-engine testing standards)

Steps of diesel engine overhauling

Inspection and necessary measurements

4


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Identify the components of diesel

engines and dismantle the internal

parts.

1-Disassembly and assembly of a

diesel engine:

Upper and lower components of diesel

engines

Dismantling of internal parts

4

Inspect and repair cylinder heads

and related attachments.

2-Cylinder head and valve service:

Removal of cylinder head

Cleaning cylinder heads

Inspection and repair of components

(cylinder head face-crack inspection-

valves-valve guides-valve seats-valve

springs-injector-seats)

Combustion chamber removal

Replacement of glow plugs

Installing cylinder head to block

8

Inspect and repair the cylinder

block.

Dismantle, install, and inspectcylinder liners.

3-Cylinder block service:

Cleaning the cylinder block

Cylinder liner measurement

Inspection of liners (out-of-roundness ovality)

Cylinder block bearing alignment

Installing cylinder liners

4


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Remove, assemble, inspect, and

replace crankshafts.

Inspect and repair flywheels.

4-Crankshaft service:

Crankshaft removal

Crankshaft apparent inspection and

measurements

Bent inspection

Crack inspection

Crankshaft polishing and grinding

Replacing crankshaft

Inspection of bearings and clearance.

Crankshaft oil seals installation

Inspection and repair of flywheels

Assembling the crankshaft into the block

6

Remove, inspect, repair, and

replace pistons and connecting

rods.

Disassemble and assemble piston

rings.

Assemble piston and the

connecting rod, and install

assembly in block

5-Pistons, rings, and connecting rod service:

Removal of pistons

Inspection and repair piston

components-ring groove

Piston dimension measurements

Assembling of rings

Connecting rod inspection (big and

small ends-alignment)

Assembly of piston to connecting rod

Installing piston and connecting rod

assembly Analysing piston and cylinder problems

6


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Remove, install, inspect, and repairvalve train assembly.

Adjust valve clearance.

Inspect and replace timing belt.

6-Valve timing service:

Camshaft removal and inspection Inspection of camshaft bearings

Inspection of cam followers-pushrods-

rocker arms and shaft

Camshaft installation

Valve clearance adjustment

Inspection and replacement of timing

belts

4


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Inspect, repair, and replace cooling

system parts.

7-Cooling system service:

Cooling system failures

Inspection, repair, and replacement of

cooling system parts (radiator-water

pump-fan-thermostat)

2

Inspect, repair and replace

lubrication system parts.

8-Lubrication system service:

Oil filters replacement

Inspection and repair of oil pump

Oil pumps assembly

Testing of leakage of oil cooler

2

Inspect and repair intake and

exhaust system parts.

9-Intake and exhaust system service:

Inspection and repair of air intake

system problems

Replacement of filters and piping

Inspection of turbochargers

Repair, assembly and testing

turbochargers

Disassembly, inspection and repair of air

blowers

Inspection and repair of exhaust system

6


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Diagnose diesel engine faults andanalyze test reports.

10-Faultfinding and testing diesel engines:

Faultfinding and testing diesel enginesusing special testing apparatus to

determine changing of: power-fuel

consumption-inlet air pressure-fuel

pressure and temperature- exhaust

pressure and temperature-engine

speed.etc.

Engine testing report analysis

10


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HEQ171CodeHydraulic and Pneumatic SystemsCourse Title

HEQ163Prerequisites

54321Trimester

3Credit Hours

(Hour/week)

1L

4W

T

Contact

Hours

(Hour/week)

Course Description:

This course covers hydraulic and pneumatic systems.

In the beginning, the system types as well as the

components and circuits are explained. Then samples

of these systems in heavy equipments are presented.

The practical part contains a number of tests for

systems components (pumps, hydraulic and

pneumatic cylinder and motors) in addition to

assembly and disassembly procedures

General Goal:

The course aims to enable the trainees to understand different hydraulic and pneumatic

systems (component, operation, circuit). Also, it gives them the necessary skills to service these

systems.



Apply the safety measures in dealing with heavy hydraulic and pneumatic systems.

Understand component function and system operation.

Perform the relevant tests and replacement work.

Understand the system particularities of heavy equipment.


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Topics

Basic concepts of hydraulics & pneumatics Hydraulics & pneumatics system types

Hydraulic system components

Application of hydraulic systems in heavy equipment

Design and drawing of hydraulic circuits

Pneumatic system components

Application of pneumatic systems in heavy equipment

Design and drawing of pneumatic circuits

Fluid Power ( Theory & Application) ,J., Sullivan

Printice Hall International, Inc., Upper Saddle River, New

York, U. S. A., 1998

Fluid Power wit Applications, A.., Esposito, Printice

Hall, Columbus, Ohio, U. S. A., 1980

Diesel Equipment, Vol.I &Vol.II, E.,J., Schulz

McGraw-Hill book Company, New York, U.S.A. 1982

Moving the Earth ( The Handbook of Excavation), H., L., Nichols, North

Castle Books, Greenwich, Connecticut,

References:




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Identify different system

components as well as how theywork.

1- Hydraulic systems:

System components (pumps, valves,

actuators)

2

Note the particular features of

heavy-duty hydraulic systems.

Hydraulic systems in heavy equipments

(system components and operation for

on-high way vehicles and off-high way

vehicles)

2

Learn how to design and drawhydraulic circuits.

Criteria of hydraulic circuit design andclassification

Circuit design procedure for (single

and double- acting) hydraulic cylinders

2

Be familiar with various system

components as well as how they

work.

2-Pneumatic systems:

System components (compressors,

valves, actuators, etc)

3

Note the particular feature of

heavy-duty pneumatic systems. Pneumatic systems in heavy equipments

(system components and operation for

on-high way vehicles and off-high way

vehicles)

2

Understand how to design and

draw pneumatic circuits. Criteria of pneumatic circuit design

procedure for (single-and double-acting)

pneumatic cylinders

2


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Be aware of safety importance. Application of safety measures related to

hydraulic and pneumatic systems2

Learn inspection testing,

mounting and demounting

procedures.

1-Determining and servicing hydraulic

system components in some heavy

equipment:

Inspection, testing, mounting,

demounting and cleaning of pumps and

accumulators

8

Learn inspection, testing,


procedures.

Inspection, removing, installation and

cleaning of hydraulic lines and fillers6



procedures.


cleaning of valves6

Learn inspection, testing


procedures.

Inspection, mounting, demounting and

cleaning of hydraulic cylinders and

motors

4

Obtain the necessary skills for

design and drawing.

Design and drawing of some simple

hydraulic circuits4


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procedures.

2-Determining and servicing pneumatic

system components in some heavy

equipments:

Inspection and testing of compressors

Mounting and demounting of some

demountable types

6



procedures.


cleaning of pneumatic lines fillers

.

4



procedures.


cleaning of valves4

Learn inspection testing


procedures.

Inspection, mounting, demounting and

cleaning of pneumatic cylinders and

motors

4

Obtain the necessary skills for

design and drawing. Design and drawing of some simple

pneumatic circuits4


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Topics

Methods of power transmission in heavy equipment

Clutches

Gear boxes

Hydrostatic transmission

Drive shafts and final drive

Inspection, repair, and adjustment of transmission system parts and joints

Diesel Equipment,Erich J.Schultz

Heavy Equipment Repair,Herbert L. NicholsReferences:


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Explain the different devices of

power transmission, as well as

identify types and advantages and

disadvantages of each.

1-Methods of power transmission:

Gears (spur-helical-planetary gears)

Chains-belts

Universal joints (couplings-constant

velocity joints)

Chain drives (roller chain-silent chain-

crawler tracks) Belt drives (pulleys-flat belts-V-belts-

conveyors)

Bearings

4

Identify the different types of

clutches used in heavy equipment

and define the parts and operation

of each.

Faults diagnose clutch parts.

2-Clutches:

Mechanical clutches (jaw clutch-single

and multi-disc friction clutches-clutch

linkages)

Clutch fault diagnosis

Hydraulic coupling

Torque converter (single and multi-

stages-oil cooling circuit)

6

Explain hydrostatic circuits for

hydrostatic transmission systems,

and system parts and operation.

3-Hydrostatic transmission:

Hydrostatic circuits

Pump to motor drives

Piston pump and variable displacement.

Swash plate control

4


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Define different types of

transmissions used in heavy

equipment and explain their

operation.

4-Transmissions:

Types of transmissions (sliding mesh-

constant mesh)

Standard transmission

Automatic shift transmission

Transfer case

8

Define the characteristics of drive

shafts and the construction of

differential carriers and final drives

used in heavy equipment.

5-Drive shafts and final drives:

Propeller shaft and joints

Differentials (types: single and double

reduction carriers-purpose of differential

gears and construction)

Final drives (types: single and double

reduction-planetary final drives)

4


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Determine faults and repairstandard transmissions.

Disassemble, assemble and install

transmission of the equipment.

Inspect and repair automatic

transmission.

Inspect and repair transfer case and

auxiliary gear box.

3-Inspection, repair, adjustment of

transmissions:

Removal and disassembly of gear boxes

Inspection of performance and repair of

standard transmission

Inspection and repair of automatic

transmission (inspection of pressure-

control valves-oil cooling circuit-

leakages)

Inspection and repair of transfer case

and auxiliary gear box

26


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Dismantle, disassemble, inspect,

repair and reinstall drive shafts and

the final drive assembly of heavy

equipment.

4-Inspection and repair of drive shafts and

final drives:

Inspection and repair of propeller shaft

and joints

Replacement of joints

Replacement of propeller shaft

Inspection and repair of differentials

Inspection and repair of final drive

assembly

12


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Topics

Fundamentals of heavy duty braking

Hydraulic brakes

Disc brakes

Drum brakes

Pneumatic brakes

Anti-lock braking systems

Diagnosis, maintenance and repair of heavy equipment brake systems

Diesel Equipment,Erich J.SchultzReferences:


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Define basic concepts of braking.

1-Fundamentals of heavy duty

braking:

Power requirement for braking

Stopping distance

Coefficient of friction

Brake lining friction

Brake torque (stopping power) Engine brakes

6

Explain hydraulic brake system

components and the function of

each part.

2-Hydraulic brakes:

Master cylinders (single tandem)

Brake pipes and hoses

Wheel cylinder

Brake drums and brake shoes

Brake pressure control valves (metering

valve-proportional valve-combination

valve)

Servo brakes

6

Explain the construction of disc

brakes and multi-disc brakes used

in heavy equipment.

3-Disc brakes:

Floating caliper disc brakes

Fixed caliper disc brakes

Multi-disc brakes

4


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Distinguish between cam and

wedge type brakes and identify the

constructional parts and the

operation for each.

4-Drum brakes:

Types of drum brakes

Cam brakes (S cam)

Wedge brakes

4

Identify air brake and parking brake

structural components as found in

heavy equipment.

Explain the operation of different

types of air brakes and tractor-

trailer brake system.

5-Pneumatic brakes:

Basic air brake system

Brake chamber

Air compressors

Brake valves (application valve-hand

application valve-dual application valve)

Air brake reservoirs

Dual air brake system

Tractor-trailer brake systems

Parking brakes

Parking brake control valve

13

Explain the purpose of anti-lock

brake system and types.

Determine components of ABS

Explain the operation of each

component.

6-Anti-lock braking systems:

Wheel speed sensors

Controllers

Pressure protection valves

6


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Identify the different components

of brake systems in heavy

equipment through dismantling and

installation of parts.

1-Heavy equipment brake system

component identification:

4

Know how to identify hydraulic

system parts.

Check and repair the master

cylinder.

Inspect, repair, and replace

hydraulic brake system parts.

Bleed air from the system.

2-Hydraulic brake system service:

Dismantling, checking, repair, and

reinstallation of hydraulic master

cylinder

Bleeding air from hydraulic system.

Inspection and replacement of brake

shoes and pads

Dismantling, disassembly, inspection,

assembly, and reinstallation of wheelcylinder

Inspection of leakage and replacement

of brake hoses

Inspection, replacement, and

reinstallation of hub

Checking brake valves

8


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Inspect, repair and replace differenttypes of brake discs.

3-Disc brake service and maintenance:

Inspection, repair, and replacement ofbrake discs

Dismantling floating and fixed calipers

Disassembly and assembly of caliper.

Cleaning, inspecting and repair caliper

Reinstalling caliper

Servicing and maintenance of multi-disc

brakes

6


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Inspect, adjust and repair cam and

wedge brakes.

4-Cam and wedge brakes service:

Inspection, adjustment and repair of cam

brake

Inspection, adjustment and repair of

wedge brake

6

Inspect and repair a brake booster.

5-Inspection and repair of brake booster

4

Identify power brake parts. Repair a brake pump.

6-Power brakes (oil):

Oil power brake parts identification Inspection and repair of brake pump

4

Inspect, adjust, and repair brake

system components.

Adjust air pressure in a brakesystem.

7-Pneumatic brake system service:

Pneumatic brake system parts

Inspection of brake air reservoir and

leakage in brake supply lines

Inspection, repair, and test of air

compressor

Inspect and test brake pressure regulator

valve

Adjust air pressure in system

Repair air brake chamber

Maintenance and repair of brake valves

Adjustment and repair of parking brakes

14


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Inspect, maintain, and repair

antilock brake systems and

components.

8-Anti-lock brake system service:

Testing, adjusting and repair of antilock

brake system

Inspection, replacement of ABS sensors

Inspection of ABS connections

Inspection and replacement of controller

6


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HEQ251CodeDiesel Engine Fuel SystemsCourse Title

HEQ172Prerequisites

54321Trimester

3Credit Hours

(Hour/week)

1L

4W

T

Contact

Hours

(Hour/week)

Course Description:

This course presents the study of different types

of diesel fuel injection systems and components

including; fuel tank, supply pump, injection pump,

injectors, and electronic diesel controls. The practical

sessions include; methods of fault diagnosis, repair

and adjustment of system components.

General Goal:

The course gives the trainees the understanding of different types of diesel fuel injection

systems and components, as well as the construction and operation of system parts. In addition

to hands on experience of faultfinding, inspection, repair, and adjustment of system components.

Behavioral Objectives:The trainees should be able to:

Identify components of a diesel fuel injection system.

Explain the construction and operation of injection system elements.

Locate faults and adjust an injection system without disassembly.

Adjust and calibrate different types of injection pumps on a test bench.

Adjust and calibrate injectors.

Repair injection pumps and injectors through replacement of defective parts.


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Topics

Diesel fuel injection systems

Fuel supply pumps

Fuel filters

Diesel fuel injection pumps (high pressure pumps)

Diesel fuel injectors

Electronic diesel control (EDC)

Fault diagnosing, repair, and adjustment of diesel fuel injection system components

Diesel Engine and Fuel Systems,Barry Wellington and Alan Asmus

Diesel and Mobile Plant Technology, Clifford M. TempestReferences:


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Identify different types of diesel

injection pumps, parts, and

operation.

Explain methods of control of

diesel fuel injection for inline and

distributor pumps.

Test and adjust injection pump on

specialized test benches.

Identify different types of speed

governors.

4-Diesel fuel injection pump (high pressure

pump):

Types of inline and distributor pumps

Assembly and operation of inline

injection pump

Assembly and operation of distributor

injection pump

Methods of injection control in inline

pump

Methods of injection control in

distributor pump

Testing and adjustment of inline pump

Testing and adjustment of distributor

pump

Speed governors (mechanical-hydraulic-

pneumatic)

4

Identify injector parts and

operation.

Test injectors on specialized testers.

5-Diesel fuel injectors:

Types of diesel fuel injectors

Construction and operation of diesel fuel

injectors

2

Identify the components of an

electronic diesel control system.

Explain the theory of operation of

electronic diesel control systems.

6-Electronic diesel control (EDC):

Electronic control system for inline and

distributor pumps

Electronic control system components

(sensors-actuators-control unit)

2


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Identify the components of diesel

fuel injection system parts.

Dismantle and install injection

system components.

1-Diesel fuel injection system parts:

Safety precaution in diesel workshops

Dismantle and installation of injection

system parts (fuel tank-supply pump-

fuel filters-injection pump-piping-

injectors)

4

Replace fuel filters.

Repair fuel supply pump.

2-Adjustment, repair, and replacement of:

Fuel filters

Supply pumps6

Identify diesel injection system

faults and possible causes.

Inspect fuel injection circuits.

Bleed air from injection circuits.

3-Testing of diesel fuel injection system on

test bench:

Simulation of fuel system faults and

relating these faults to possible causes

such as hard starting, loss of engine

power, irregular engine running, engine

knock...etc.

Apparent inspection of piping, hoses,electrical connections, to determine

leakage and faults.

Injection timing

Smoke testing

Bleeding injection system

Repair and replacement of supply lines

(high pressure tubes-return pipes-filters)

10


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Inspect, repair, test, and adjust

injectors.

4-Adjustment, repair, and testing of

injectors:

Disassemble, cleaning repair and

reassembly of injector

Inspection and repair of injector

Injector testing (leakage-injection

pressure-dribble-atomization tests)

8

Adjust inline injection pump on

high pressure pump test stand.

5-Testing and adjustment of inline injection

pump:

Use of high pressure pump test bench to

determine: leaks-rack position-fuel spill

off-fuel quantity at different rpm and

positions of control rack

Compare results with manufacturer data

6

Adjust distributor injection pump

on high pressure pump test stand.

6-Testing and adjustment of distributor

injection pump:

Use of high pressure pump test bench to

test: transfer pump-automatic advance-

maximum fuel delivery-fuel cut off-governor setting-injection timing

Compare results with manufacturer data

6


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Replace the inline and distributor

injection pump elements.

7-Repair of inline and distributor injection

pumps:

Replacement of defective parts in diesel

injection pumps such as: injection

elements-cam plate-springs-injection

timer spring-bearings-delivery valves

8

Inspect and replace the components

of electronic diesel control systems.

8-Inspection and replacement of electronic

diesel control systems:

Inspection of EDC elements (sensors-

actuators-controller)

Replacement of the components of

diesel injection electronic control

systems

8


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Department Mechanical Technology Major Engines and Vehicles

Course name Technical Drawing Code HEQ 254

Prerequisite 164MEV

Course description:

In this course the identification of types of

technical drawings (including the use ofgraphical charts) to indicate the relationship of

different parameters in vehicle area, and the

use of schematic drawings to indicate the

components of different vehicle mechanical

and electrical systems, their symbols and

stages of operations will be covered. The

course also includes the use of engineering

drawing to draw vehicle components and

elements, as well as the use of assemblydrawing and sections of vehicle system parts.

Trimester 1 2 3 4 5

Credit hours 2

L -

W 4 Contact

hoursT -


This course aims at training the automotive technician trainees to conceive and follow up the

illustrative diagrams of circuits and parts included in technical maintenance books. This helps

the trainees to understand the relationships of different parameters affecting parts operation and

performance, and acquisition of the necessary skills to use technical drawing as a means of

illustration and conveyance of ideas.


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Detailed ObjectivesRequired Performance

SpecificationsRelated Tasks

First: Procedural Objectives:


1) Draw schematic diagrams (vehicle system

circuits steps and stages of operation of

vehicle units).

-Drawing of circuits

(electrical electronic

mechanical)

2) Draw engineering drawings for vehicle

system elements.

-Drawing of fittings and

power transmission

elements

B5, B8, C5, D4,

D7, D8, D10,

G1, G10, G16,

H1..H5, K4, L3,

E9..E11, F4,

G13, G14,

I1..I4, I8, I9,

I!2..I14, I16,

J11, K10, K15,

K16

3) Apply engineering drawing to draw parts

and units of vehicle systems.

-Assembly drawing for

sectioned parts and

units of vehicle system

and locating

dimensions on them

E8, F5, G3, H1,

H2, I1, J4

Second: Auxiliary Objectives (Cognitive and

Behavioral):The trainees should be able to:

1) Understand the graphical charts. -Explanation of parts design and

construction

A9

2) Understand diagrams in books and

catalogues.

-Writing of technical reports C5

3) Express technical ideas using drawings. -Writing of technical reports H7,

I19,K20

Safety Requirements:

Clean place of work with good ventilation and lighting.


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Subjects (Theoretical and Practical) Related Tasks

Graphical charts

Schematic diagrams

Assembly drawing

Exploded drawing (individual for internal parts of

components)

Application of engineering drawing

B9,

C5

-Understand technical drawings and

become familiar with maintenance

and repair books



8Technical drawings:

-

Identification of the types of technical drawings

8

Graphical drawing:

-The purpose of graphical drawing

-Types of graphical drawings

-Method of representation of graphical drawings

-Applications on graphical drawings

14

Schematic diagrams:

-The purpose of schematic diagrams

-Types of schematic diagram

-Symbols used in schematic diagrams

-Applications on schematic diagrams

Direct observation

Written questions


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22

Applications of engineering drawing:

-Fasteners and their attachments (bolts rivets welding)

-Power connection elements and attachments (shafts keys

splines sliding bearings roller bearings seals)

-Power transmission elements and attachments (sprockets

gears cams springs)

-Assembly drawing and sections of some vehicle systems


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References:

1-

GTZ, Technical Drawing for Automotive Engineering.

2- Ahed Ali Alkhateeb, Engineering Working Drawing, Dar Al-

Kheraiji for Publication & Distribution , 2002, ISBN 9960-879-09-7


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HEQ261CodeHydraulic and pneumatic system

MaintenanceCourse Title

HEQ171Prerequisites

54321Trimester

4Credit Hours

(Hour/week)

2L

4W

T

Contact

Hours

(Hour/week)

Course Description:

This course covers the maintenance procedures for

hydraulic/ pneumatic components and systems. It

explains maintenance requirements and how somefactors (seals, filters, fluid pressure & temperature)

can affect system performance and protection. Also,

the course gives recommended maintenance

procedures for two systems (hydraulic and pneumatic)

in heavy equipments. The practical part of the course

contains a set of tests and maintenance services for the

previously taught systems.

General Goal:

To convey to the trainees the principles of different maintenance procedures, and the various

factors affecting system conditions. In addition to the required training to perform maintenance

services.



Know the important factors to check for system protection and maintenance.

Know the required maintenance procedures for hydraulic/pneumatic components andsystems.

Carry out maintenance for heavy-duty hydraulic and pneumatic systems using instruction

manuals.

Check the repaired components using a hydraulic test bench.


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Develop a strong sense of safety

importance

Complete maintenance forms

1-Basic maintenance concepts:

explanation of meaning of:

Preventive maintenance, maintenance

sheet, etc

Safety rules during maintenance

operations

4

Evaluate the component and system

conditions based on a check of the

relevant factors

2-Important factors to be considered for

hydraulic and pneumatic system

maintenance:

Study the effects of: (lubricating oil,

seals, filters, gaps between moving

parts, gas and particle leakage to the

system, temperature and pressure

variations)

10

Perform the correct maintenance

procedure for heavy-duty hydraulic

systems

3-Recommended procedures to perform

component maintenance for heavy-duty

hydraulic systems:

Determination of list of steps in

sequence to service pump, valves, etc

6

Perform the correct maintenance

procedure for heavy-duty

pneumatic systems

4-Recommended procedure to perform

component maintenance for heavy-duty

pneumatic systems:

Determination of list of steps insequence to

heavy equipment1

Documents