manual darr en ingles.doc

SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE

DEFINITIONPERFORMANCE SKILL 1

TITLE: Demonstrate Measuring and Adjusting Fuel Rack Setting on Forged Body Injection Pump.

EQUIPMENT REQUIRED: Engine with Forged Body Fuel injection pump. (D398, D399, D343 S/N 62B or D342 S/N 31B) Fuel Setting Information 6V-9128 Tool Group or (9S0240 Tool Group or 3H1690 Gauge Rack Setting)

PROCEDURE:

Install correct tooling Measure fuel setting Adjust fuel setting Seal with governor seal

REFERENCE: Service Manual Check S.I.S. or S.I.R.S and FIND for the latest updates

I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).

This skill has been demonstrated to me by the individual listed above. __________________________________________________(Signature & Emp #)

Signature of Supervisor ____________________ DATE .

REVISED 2001


DEFINITION PERFORMANCE SKILL 2

TITLE: Demonstrate Measuring and Adjusting Fuel Rack and Air Fuel Ratio Valve Setting on a Compact Fuel System

EQUIPMENT REQUIRED:

9S0240 Tool Group(Disc.) or 6V9128 Tool Group Compact Fuel System (3304, 3306 or D343 Engine) Continuity Light or Multimeter Rack Setting Charts or Engine Performance Specs. 5P1660 Governor Sealing Tool Group (Disc.) or Plastic Governor Seal

PROCEDURE:

1. Install correct tooling. 2. Measure fuel setting using continuity light or multimeter. 3. Adjust fuel setting. 4. Seal with governor seal group.

REFERENCE:

Service Manual Special Instructions – SEHS8436 Video Tape 42 – Hydraulic Air-Fuel Ratio Control Adjustment - JEGO9042 (¾ “) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring and Adjusting Fuel Setting (Sleeve Metering Fuel System)

EQUIPMENT REQUIRED:

5P4203 Gauge Group Fuel Setting Charts or Engine Performance Specs. Sleeve Metering Fuel System Continuity Light (or Multimeter)

PROCEDURE:

1. Install correct tooling. 2. Measure fuel setting using continuity light or multimeter. 3. Adjust fuel setting. 4. Seal with governor seal.

REFERENCE:

Service Manual Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Engine speed and Set Point with 6V3121 Multitach and 6V4060 Set Point Indicator or 9U7400 Tool Group

EQUIPMENT REQUIRED:

6V3121 Multitach Group (Disc.) 6V4060 Set Point Indicator (Disc.) 9U7400 Tool Group Fuel Setting Information or Engine Performance Specs. Tachometer Drive Adapters 5P7360 Tachometer Generator or 6V4950 Injection Line Speed Pickup Group

PROCEDURE:

1. Install correct tooling. 2. Measure high idle RPM using tach generator, photo cell and fuel line pickup. 3. Measure low idle RPM. 4. Measure Set Point

REFERENCE:





REVISED 2001

SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE


TITLE: Demonstrate Proper Use of Electric Lift Truck Battery Charger

EQUIPMENT REQUIRED:

Electric Lift Truck Battery Charger

PROCEDURE:

1. Check battery for proper electrolyte level. 2. Properly connect charger leads to battery or multimeter. 3. Charge battery according to Battery Service Manual procedure.

REFERENCE:

Lift Truck Video Tape 32 - PM on Electric Lift Trucks – SEVV7032 (¾”) Battery Service Manual - SEBD0625 Pages 29 - 32 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:

Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 5P4767 or 4C3048 Battery Lifting Bar Assembly

EQUIPMENT REQUIRED:

Electric Lift Truck with Battery 5P4767 or 4C3048 Battery Lifting Bar

PROCEDURE:

1. Properly remove and install electric lift truck battery according to Service Manual procedure.

CAUTION: If using lift truck, properly secure lifting bar to lift truck to keep lifting bar from sliding off forks.

REFERENCE:

Service Manual L.T. Technical Bulletin Feb. 19, 1971 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Timing Dimension (Compact Fuel System)

EQUIPMENT REQUIRED:

5P6600 Lifter Setting Tool Group 5P4165 Indicator Group 6V2012 Gauge Group

PROCEDURE:

1. Install correct tooling for fuel system being calibrated. 2. Measure timing dimension using depth micrometer. 3. Measure timing dimension using dial indicator. 4. Adjust timing dimension on one pump using either tool.

REFERENCE:

Service Manual Special Instructions - SEHS8980 Video Tape 88 – Fuel Injection Pump Recon. SEVV9088 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Torque procedure using Torque Wrench, Torque Multiplier, and Torque Wrench Extension.

EQUIPMENT REQUIRED:

9S7353 Torque Wrench or equivalent Torque Wrench Extension Torque Multiplier

PROCEDURE:

1. Make sure hardware is clean and lubricated. 2. Make correct initial torque. 3. Rotate hardware to correct final position. 4. Calculate torque using a torque wrench extension. 5. Demonstrate tightening hardware using torque wrench and torque multiplier and calculate resulting torque.

REFERENCE:

Service Manual Video Tape 44 Part 2 - Working with Pullers, Torque Wrenches, Multipliers - SEVN9044 (½”) Slide Rule Computer - SEHS7150 Special Instructions - SMHS7657 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:

Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 6V7070 or 6V7800 Digital Multimeter, using the Voltage, Resistance, and Diode Switch Positions.

EQUIPMENT REQUIRED:

Digital Multimeter Electrical Components: 1. Fixed Value Resistor 2. Capacitor 3. Diode 4. Power Transistor 5. Zener Diode 6. DC Power Source

PROCEDURE:

Follow Procedure Outlined in the Reference Literature

NOTE: Obtain Specifications from the Service Manual for Power Transistor

REFERENCE:

Service Manual Special Instruction - SEHS7734 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Correct Liner Projection Measurement

EQUIPMENT REQUIRED: LIFT TRUCK HEAVY EQUIPMENT XN1P Gas Engine 1P5510 Tool Group 8T0501 Dial Indicator Engine 8T0502 Indicator Base T - Bar 8T0472 Liner Compressor Tool 8T0476 Cylinder Liner Clamp

PROCEDURE: 1. Measure liner projection of all cylinders according to Service Manual or Special Instructions. 2. Follow procedure and measure carefully. 3. Note all readings for reference and comparison. 4. For XNIP Engine, use selection chart in Service Manual to determine liner gasket. 5. Record your findings on worksheet # 13 - 13A and attach to this form.

REFERENCE: Service Manual Special Instructions - SMHS7727 Video Tape 43 – Cylinder Block Counterboring – JEGO9043 (¾”) Video Tape 47 – Cylinder Block Liner Seat Sleeving – JEGO9037 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Piston Ring Land Wear

EQUIPMENT REQUIRED:

Standard Design Piston Keystone Design Piston 5P3519 Piston Ring Groove Gauge 5P4812 Piston Ring Groove Gauge 8S2304 Piston Ring Groove Cleaner

PROCEDURE:

1. Measure ring grooves according to instructions in Reusable Parts Guide. 2. Record your findings on worksheet #15 and attach to this form.

REFERENCE:

Guideline for Reusable Parts - Form SEBF8049 Instruction Card - SEES5544 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Clearance of Rod and Main Bearings and Checking Crankshaft for Reusability

EQUIPMENT REQUIRED:

Engine Micrometers Plastigage "V" blocks and Dial Indicator Torque Wrench

PROCEDURE:

1. Measure clearance according to specifications. 2. Make recommendation for reusability of bearings. 3. Make recommendation for reusability of crankshaft. NOTE: Lead wire no longer used. 4. Record your findings on worksheet #14 and attach to this form.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Measuring Turbocharger Shaft Straightness

EQUIPMENT REQUIRED:

Turbocharger Shaft 5P6518 Parts Reusability Fixture Group

PROCEDURE:

1. Measure shaft according to guidelines in special instruction.2. Check for excess bend and compare to specifications

REFERENCE: Special Instructions – SMHS6998 Video Tape 54 - Turbo Reconditioning 1 - JEGO8054 (¾”) Video Tape 56 - Turbo Reconditioning 2 - JEGO9056 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Air Intake System for Leaks at Joints

EQUIPMENT REQUIRED:

Engine - with Complete Air Intake System Plastic Bag Air Pressure Regulator Soap Solution

PROCEDURE:

1. Conduct test according to P.M.P. special test #6. 2. Make recommendation for corrections if necessary.

REFERENCE:

Special Tests - SENU6176 or SENU6179 Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate on Engine Adjustment of Hydraulic Air Fuel Ratio Control on New Scroll Fuel Systems

EQUIPMENT REQUIRED:

1. Engine with Hydraulic Air Fuel Ratio Control and New Scroll Fuel System.2. 6V6070 Tool Group

PROCEDURE:

1. Follow procedure outline in the Service Manual

REFERENCE:

Service Manual Video Tape 182 - Test And Adjusting The Hydraulic Fuel Ratio Control on “B” Series Engines - SEVV9182 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates



Signature of Supervisor ____________________ DATE__________

REVISED 2001



TITLE: Demonstrate Adjusting of Hydraulic-Air Ratio Control on Compact Fuel System

EQUIPMENT REQUIRED:

9S0240 Rack Setting Tool Group (Disc) or 6V9128 Tool Group 8S4627 Continuity Light (Disc) or 8T0500 Continuity Light

PROCEDURE:

1. Install correct tooling 2. Follow guidelines in Service Manual

REFERENCE:

Service Manual Video Tape 42 - Hydraulic Air-Ratio Control Adjustment - JEGO9042 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Correct Valve Lash and Jake Brake Adjustment on Current Engines

EQUIPMENT REQUIRED:

Engine (Pushrod) (Heavy Equipment and Lift Truck Technicians) Engine With Jake Brake (Truck Engine Technicians) Engine Turning Tool Feeler Gauge Jake Brake Gauge

PROCEDURE:

1. Follow procedure as outlined in Service Manual. 2. Follow procedure as outlined in the Jake Brake Service Manual. (Truck Engine Technicians only)

REFERENCE:

Service Manual Lubrication and Maintenance Guide Jake Brake Installation Manual Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Refacing Valves and Valve Seats

EQUIPMENT REQUIRED:

Valves Cylinder Head Valve Refacing Machine Valve Seat Refinishing Tools

PROCEDURE:

1. Clean valves. 2. Reface valves and valve seats according to guidelines. 3. Show line contact between valve and valve seat.

4 . Be aware of difference between seat angle and valve angle for "Interference Grinding."

REFERENCE:

Service Manual Special Instructions - SMHS6998 Video Tape 55 - Knurling Valve Guides – LEVN9055 (½”) Video Tape 62 – Cylinder Head Reconditioning – JEGO9062 (¾”) Video Tape 63 – Valve Grinding – JEGO9063 (¾”) Check S.I.S. or S.I.R.S and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Cylinder Head for Reusability

EQUIPMENT REQUIRED:

Cylinder Head Straight Edge Feeler Gauge Magna-Flux Group Liquid Dye Kit

PROCEDURE:

1. Clean head thoroughly. 2. Follow videotape instructions.

REFERENCE:

Service Manual Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Video Tape 63 – Valve Grinding JEGO9063 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Load Sensing, Pressure Compensating Hydraulic System

EQUIPMENT REQUIRED:

Gauge Group Appropriate Machine

PROCEDURE:

1. Measure system maximum pressure. 2. Measure system margin pressure. 3. Measure system low pressure standby. 4. Record your findings on worksheet #16 and attach to this form.

REFERENCE:

Service Manual Video Tape 202 - Pressure Compensated Load Sensing Hydraulic System SEVN9202 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Fuel For Specific Gravity

EQUIPMENT REQUIRED:

1P7408 Thermo-Hydrometer – Range 29º- 41º API 5P2712 Thermo-Hydrometer – Range 39º- 51º API 1P7438 Beaker Diesel Fuel

PROCEDURE:

1. Measure fuel apparent specific gravity using hydrometer and beaker. 2. Correct API reading for barometric pressure, ambient temperature, etc.,

according to Special Instructions. 3. Record your findings on worksheet # 17 and attach to this form.

REFERENCE:

Special Instructions - GMGO0977, and SEHS7067 Service Magazine - 8/29/74 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Fuel Injection Nozzles

EQUIPMENT REQUIRED: 5P4150 Nozzle Tester Group Direct Injection Nozzle (Capsule Type) Direct Injection Nozzle (Pencil Style) Precombustion Chamber Nozzle Fuel Collector PROCEDURE: 1. Test all three types of fuel nozzles according to guidelines. Sequence DI Nozzle: 1. Install nozzle. 4. Flush nozzle 2. Pressure loss test. 5. Tip Leakage Test. 3. Valve opening pressure (VOP) test. 6. Orifice restriction test. .

2. Sequence PC Nozzle: (NOT REQUIRED FOR TRUCK ENG.SPEC.) 1. Install nozzle. 2. Pressure loss test. 3. Valve Opening Pressure (VOP) test. 4. Record your findings on worksheet #18 and attach to this form.

REFERENCE: Service Manual Video Tape 139 – Testing Pencil-Type Nozzles SEVV9139 (¾”) Video Tape 167 – Fuel Nozzle Testing SEVV9167 (¾”) Special Instructions - SEHS7292, SEHS7350, SEHS7390 Lift Truck Video Tape 42 - Testing Perkins Nozzle SEVV7042 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates


This skill has been demonstrated to me by the individual listed above. __________________________________________________(Signature & Emp #) Signature of Supervisor ____________________ DATE .

REVISED 2001



TITLE: Demonstrate Testing a Cooling System and Components.

EQUIPMENT REQUIRED:

9S8140 Pressurizing Pump Regulators Machine Heat Source Thermometer Conditioner test kit Coolant Tester Radiator Cap

PROCEDURE:

1. Pressurize system with air and check for leaks. 2. Heat regulators and measure opening temperature and fully open temperature. 3. Measure Coolant freeze point and conditioner concentration. 4. Test cap with pump and compare with specifications.

REFERENCE:

Service Manual Know Your Cooling System - SEBD0518 Video Tape 96 – How to Use Cooling System Diagnostic Tools – Pressurizing Pump SEVN9096 (½”) Lift Truck Video Tape 23 – Lift Truck Cooling Systems Troubleshooting SEVV7023 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Water Temperature Regulators

EQUIPMENT REQUIRED:

Regulators Thermometer (6H3050 or 7F7112 or 9S9102) Container of water Heat Source

PROCEDURE:

1. Measure opening temperature.2. Measure temperature regulator when fully open, compare to specifications.

REFERENCE:

Service Manual Know Your Cooling Systems- SEBD0518 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Coolant for Freezing Point and Inhibitor Concentration

EQUIPMENT REQUIRED:

Coolant Samples 8T5296 Coolant Conditioner Kit 5P0957 Coolant Tester Commercial Anti-freeze Tester 5P9734 Coolant Syringe

PROCEDURE:

1. Measure freezing point of ethylene glycol solution using both testers. 2. Test sample for conditioner concentration.

REFERENCE:

Know Your Cooling System Booklet – SEBD0518 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Glow Plugs

EQUIPMENT REQUIRED:

Glow plugs form Caterpillar engine or Lift Truck engine with glow plugs Electric test bench Digital Clamp on ammeter Digital Multimeter Digital multimeter

PROCEDURE:

Caterpillar Engines

1. Test glow plugs on electric test bench for operation and current draw.2. Test glow plugs on machine using vehicle ammeter.

Lift Truck

1. Follow procedure as written in Service Manual.

REFERENCE:

Service Manual Video Tape 86 – Cold Weather Starting and Operation SEVN9086 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:

Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Use of Battery Charger, and testing a Lead Acid Battery.

EQUIPMENT REQUIRED: Battery 4C4910 or 4C4921 Battery Charger (or Commercial Charger) 5P9735 Coolant and Battery Tester VOM, 8T0900 Ammeter, 4C4911 Battery Load Tester

PROCEDURE: 1. Correctly connect charger to battery for charging. 2. Check electrolyte level and specific gravity. 3. Test Battery according to guidelines in Special Instructions 4. Charge according to Special Instructions.

REFERENCE: Special Instructions - SEHS6891 Special Instructions - SEHS8268 Battery Service Manual - SEBD0625 Electric Lift Truck T/S Series Part 1 Module 4 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Test a Lead Acid Battery

EQUIPMENT REQUIRED: Battery 5P9735 Battery Fluid Probe Digital Multimeter 5P0957 Coolant and Battery Tester Clamp on Ammeter 5P0300 Electrical System Tester or 6V4930 Battery Load Tester

PROCEDURE:

1. Use battery tester and check specific gravity.2. Test battery according to guidelines in Special Instructions

REFERENCE:

Special Instructions – SEHS8268 Battery Service Manual – SEBD0625 Lift Truck Video Tape 25 – Lift Truck Battery Servicing SEVV7025 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Battery Jumper Cables

EQUIPMENT REQUIRED: Electrical System with Discharged Battery or Batteries Booster Battery or Batteries Jumper Cables

PROCEDURE:1. Connect one end of the first jumper cable to the positive post of the discharged battery (for 24Vconnect to the positive post closest to the starter).2. Connect the other end of the first jumper cable to the positive post of the charged battery (for 24V connect to positive post closest to starter).3. Connect the second jumper cable to negative post of charged battery (for 24V, connect to the negative post closest to the frame or ground).4. Connect the other end of the second cable away from the battery to the frame or suitable ground of the machine with the discharged battery or batteries.

REFERENCE: Battery Service Manual - SEBD0625 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Stall Speed of Torque Converter/Divider

EQUIPMENT REQUIRED: 6V3121 Multitach Group Fuel Setting Charts Tachometer Drive Adapters (if needed) Machine Equipped with Torque Converter/Divider 6V4160 Transmission Test Group (if needed)

PROCEDURE: 1. Connect correct tooling to measure machine being tested. 2. Measure engine high idle and low idle RPM. 3. Measure torque converter/divider stall speed.

PRECAUTION - Run torque converter stall only as long as absolutely necessary. Damage could result if prolonged stall conditions exist.

REFERENCE: Service Manual Lift Truck Video Tape 8 – Troubleshooting The 2-speed Power Shift Transmission SEVV7008 (¾”) Lift Truck Video Tape 9- Troubleshooting The 3-speed Power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52- Single Speed Power Shift Transmission Orientation, Test & Adjust SEVV7052 (¾”) Special Instructions - SEHS7807 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Steering and Brake Pressure on a High Drive Tractor

EQUIPMENT REQUIRED: High Drive Track Type Tractor 6V4161 Pressure Gauge Kit

PROCEDURE: 1. Test steering and pressures as outlined in Service Manual. Record your findings on worksheet #19 and attach to this form.

REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 8T0450 Thread Identification Kit

EQUIPMENT REQUIRED: 8T0450 Thread Identification Kit Assortment of Metric and Standard bolts, nuts, and fittings.

PROCEDURE: 1. Measure thread diameter using the 8T0447 Dial Caliper. 2. Measure thread pitch using the 8T0448 Pitch Gauge. 3. Measure fitting seat angle using the 8T0449 Seat Gauge. 4. Measure line seat angle using the 8T0451 Seat Angle Gauge.

REFERENCE: Special Instructions - SEHS8429 Check the S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Pressures of Transmission System

EQUIPMENT REQUIRED: Track-Type Tractor 6V4160 Transmission Test Group

PROCEDURE:

1. Connect tooling to test pressures of transmission pump, torque converter inlet, torque converter outlet, transmission lube, initial pressure, speed clutch, directional clutch, steering clutch and brakes. 2. Conduct test according to guidelines in Service Manual. 3. Record information and compare to specifications. 4. Record your findings on worksheet #20 and attach to this form.

REFERENCE:

Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Bevel Gear/Pinion Adjustments

EQUIPMENT REQUIRED: Bevel Gear/Pinion Spring Gauge 8S2328 Dial Indicator 1P2390 Pinion Depth Gauge Lubriplate or suitable substitute 1P67 Spreader

PROCEDURE:

1. Measure bevel gear shaft bearing preload. 2. Measure and adjust bevel gear/pinion backlash. 3. Measure and adjust tooth contact pattern.

REFERENCE: Service Manual Video Tape 176 – 936 Wheel Loader Differential Bearing Adj. SEVN9176 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluation of Duo-Cone Seal Groups

EQUIPMENT REQUIRED: Duo-Cone Seal Groups

PROCEDURE: 1. Compare worn seal groups with guidelines and determine reusability.

REFERENCE: Video Tape 188 - Duo-Cone Seal Assembly SEVV9188 (¾”) Service Magazine - 11/4/85 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Steering Clutch Springs

EQUIPMENT REQUIRED: New and Worn Steering Clutch Springs 5P4145 Tester 1P7460 Torque Tester

PROCEDURE: 1. Test springs according to guidelines in Service Manual.

REFERENCE: Service Manual Video Tape 71 – Rebuilding Oil-type Steering Clutches SEVN9071 (½”) Special Instructions - GMGO2591 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Completion of S.I.M.S. (Service Information Management Systems) and Service Report.

EQUIPMENT REQUIRED:

Service Reports Parts Book or Parts Fiche or SIS CD’s or SIS Web

PROCEDURE:

1. Fill out report2. Follow directions found in reference material.3. Record your findings on worksheet #22 and attach to this form.

REFERENCE:

Guidelines to follow in Reporting SIMS Information (SEBD0809) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Adjusting Motor Grader Circle Drawbar

EQUIPMENT REQUIRED: "G" Series Motor Grader Hand Tools Feeler Gauges

PROCEDURE: 1. Follow procedures outlined in the Service Manual or Maintenance Manual.

REFERENCE: Service Manual Special Instructions - SMHS7185 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing I.C.M. Transmission Using Electronic Switching Control

EQUIPMENT REQUIRED: Machine with I.C.M. Transmission Hand Tools

PROCEDURE: 1. Follow procedures outlined in the Service Manual.

TEST: Transmission hold switch, lever switch, transmission gear switch, upshift, downshift, and lockup solenoids.

REFERENCE:

Service Manual Video Tape 177 – Electronic Transmissions Control System with Individual Clutch Modulations SEVN9177 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated Track

EQUIPMENT REQUIRED: Section of Sealed Track Track Press

PROCEDURE:

1. Demonstrate correct procedure in turning pins and bushings.

REFERENCE:

Reconditioning Bulletin MP-12 (4/79) - SEBF8518 Video Tape 98 – Sealed and Lubricated Track Reconditioning SEVN9098 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Disassembly and Assembly of Sealed and Lubricated Track

EQUIPMENT REQUIRED:

Section of S.A.L.T. 5P3010 Deburring Tool Track Press 5P7419 Plug Installer 5P7392 Stopper Installation Group 5P2420 Testing and Lubricating Group 5P2384 Pump Assembly (w/5P2383 Brush)

PROCEDURE:

1. Turn pins and bushings according to guidelines. 2. Follow warnings given in Service Manual. 3. Compare Track Parts to guidelines and determine reusability

REFERENCE:

Guideline for Reusable Parts - SEBF8022 Reconditioning Bulletin MP-12 (4/79) - SEBF8518 Video Tape 98 – Sealed and Lubricated Track Reconditioning SEVN9098 (½”) Wall Chart - SEWV1339 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Shoe Brake Adjustment

EQUIPMENT REQUIRED:

Wheel Machine

PROCEDURE:

1. Adjust shoe brake according to guidelines. 2. Use correct sequence and proper dimensions.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Charging Nitrogen Accumulator

EQUIPMENT REQUIRED:

7S5437 Charging Group or equivalent Nitrogen Accumulator Nitrogen Bottle

PROCEDURE:

1. Charge accumulator according to guidelines. 2. Correct for ambient temperature. 3. Follow procedure in appropriate Service Manual.

REFERENCE:

Service Manual Special Instruction - SMHS7215 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Connection of a Hydraulic Flow Meter

EQUIPMENT REQUIRED:

Hydraulic Flow Meter Machine

PROCEDURE:

1. Connect correct tooling for machine being tested. 2. Perform systems test according to Service Manual. 3. Interpret results according to Service Manual guidelines. 4. Record your findings on worksheet # 23 and attach to this form.

REFERENCE:

Service Manual Special Instructions - SEHS7097-01 and SMHS7308-00 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Torque Multiplier

EQUIPMENT REQUIRED:

Torque Wrench Torque Multiplier

PROCEDURE:

1. Demonstrate tightening hardware using torque wrench and torque multiplier.2. Calculate resulting torque applied to hardware.

REFERENCE:

Video Tape 44 - Torque Wrenches, Multipliers SEVN9044 (½”) Video Tape 77 - Reconditioning Hydraulic Cylinders SEVV9077 (¾”) Special Instructions – SEHS7150 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Four Step Hydraulic Cylinder Drift Rate Test

EQUIPMENT REQUIRED:

Stopwatch Machine with double acting cylinders Scale or Tape Measure

PROCEDURE:

1. Perform drift rate measurements according to guidelines. 2. Measure drift both in and out; with control valve in hold and shifted. 3. Evaluate results.

REFERENCE:

Service Manual SENR4178 (D7H Tractor Hydraulics) or other text with four step method





REVISED 2001



TITLE: Demonstrate Evaluating Worn Vane Pumps

EQUIPMENT REQUIRED:

Worn Vane Pumps

PROCEDURE:

1. Evaluate worn vane pumps according to Failure Analysis Book. 2. Analyze what original cause of failure was and steps to correct.

REFERENCE:

Guidelines for Reusable Parts - SEBF8080 - SEBF8025 Diagnosing Hydraulic Pump Failures - SEBD0501 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluating Worn Gear Pumps

EQUIPMENT REQUIRED:

Worn Gear Pumps

PROCEDURE:

1. Evaluate worn pumps according to guidelines.

REFERENCE:

Diagnosing Tyrone Gear Pump Failures - FEG45137 Service Magazine - 4/28/71 Service Manual - REGO0756 - Series "30" Pump Guidelines for Reusable Parts - SEBF8073 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 6V2150 Starting and Charging System Analyzer Group.

EQUIPMENT REQUIRED:

6V2150 Starting and Charging System Analyzer Group Appropriate Machine

PROCEDURE:

1. Connect the harness from the 6V2150 starting and charging analyzer to the vehicle diagnostic connector.Do the test procedure in four steps in order. A. Hookup C. Start Aid B. Crank D. High Idle

2. Record your findings on worksheet #24 and attachto this form.

REFERENCE: Appropriate Service Manual Special Instructions – SEHS7768 Video Tape 165 – 6V2150 Starting/Changing Analyzer Group SEVV9165 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate These Reinforcements: 1) Standard Beam, 2) Mounting Plate, 3) Corner, 4) Gusset

EQUIPMENT REQUIRED: Welding Machine Electrodes Metal

PROCEDURE:

1. Demonstrate standard beam weld reinforcement. 2. Compare to welding standard for appearance quality. 3. Demonstrate other reinforcements with cardboard patterns.

REFERENCE:

Hobart Pocket Welding Guide Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate These Types of Welds: 1) Fillet, 2) Groove, 3) Bead, 4) Plug

EQUIPMENT REQUIRED:

Welding Machine Metal Electrodes

PROCEDURE:

1. Demonstrate each type of weld bead. 2. Compare to welding standard for appearance quality.

REFERENCE:

Hobart Pocket Welding Guide Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate These Types of Weld Joints: 1- Butt, 2- Corner, 3- Lap, 4- Tee

EQUIPMENT REQUIRED:

Welding Machine Electrodes Metal

PROCEDURE:

1. Demonstrate each type of weld joint. 2. Compare to welding standard for appearance quality.

REFERENCE:

Hobart Pocket Welding Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate These Weld Positions: 1- Flat, 2- Horizontal, 3- Vertical, 4- Overhead

EQUIPMENT REQUIRED:

Welding Machine Electrodes Metal

PROCEDURE:

1. Demonstrate each weld position. 2. Compare to welding standard for appearance quality.

REFERENCE:

Service Welding Guide - SEBD0512 Hobart Pocket Welding Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Completion of Predelivery Inspection Report

EQUIPMENT REQUIRED:

A rubber tire machine or a track-type tractor or a lift truck or engine Correct predelivery inspection report for each machine

PROCEDURE:

1. Inspect machine following the guidelines found on the "Predelivery Inspection Report."2. Mark this report as a "SAMPLE" if it is not going to be processed via dealer terminal.

REFERENCE:

Guidelines to Follow in Reporting SIMS Information SEBF0809 Video Tape SENN8003 - Time Well Spent (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates.




REVISED 2001



TITLE: Demonstrate Use of Technical Information File

EQUIPMENT REQUIRED:

Technical Information File Microfiche Viewer

PROCEDURE:

1. Locate three (3) items for industrial engines, 2. Locate three (3) items for truck engines. 3. Locate three (3) items for electric sets.

Record your findings on worksheet # 21 listing each item, date and media number of the Microfiche where found and attach to this form.

REFERENCE:

Instruction with Microfiche Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Specifications Manual or Microfiche or Service Information Systems (SIS)

EQUIPMENT REQUIRED:

Specification Manual or Microfiche or Service Information Systems (SIS)

PROCEDURE:

1. Locate three (3) specifications for industrial engines.2. Locate three (3) specifications for vehicle engines.3. Locate three (3) specifications for power train.4. Locate three (3) specifications for

Record your findings on worksheet # 21 listing each item, date and media number where found and attach to this form.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Service Manual and Service Manual Microfiche

EQUIPMENT REQUIRED:

Service Manual Service Manual Micro Fiche and Viewer

PROCEDURE:

1. For each Section give page number date and media number of: A. One testing and adjusting procedure. B. Two specifications. C. Two disassemble and assemble procedures. D. Lubrication Intervals Chart

Record your findings on worksheet # 21 listing each item, date and media number where found and attach to this form.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Fuel Setting and Related Information Microfiche

EQUIPMENT REQUIRED: Fuel Setting and Related Information Microfiche Viewer Microfiche Library

PROCEDURE:

1. Find three (3) settings for vehicles. 2. Find three (3) settings for truck engines. 3. Find three (3) settings for industrial engines. List following information: a. Equipment Model b. Serial Number c. Application d. Altitude

Record your findings on worksheet # 21 and attach to this form.

REFERENCE:

Special Instructions - SEHS8417 Check Special Instructions for the latest update. Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Radial and Axial Alignment

EQUIPMENT REQUIRED:

8S2328 Dial Indicator Group or 8T1000 Electronic Position Indicator Group (if available)

PROCEDURE:

1. Check axial and radial eccentricity according to Service Manual procedure.2. Analyze results and make recommendations for corrections if needed.3. Record your findings on worksheet #25 and attach to this form.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of SIRS Index and FIND SIRS to Service Literature.

EQUIPMENT REQUIRED: Microfiche Library Microfiche Viewer Corporate Computer

PROCEDURE:1. Find the date & form # for LTTB that talks about "Use the correct bolts to mount the drive axle". (For Lift Truck)2. Find the date & form # for LTTB that talks about "Discharge head capacitor so self diagnostics will function" on model MC60D. (For Lift Truck)3. Find LTSL date & PSP # that talks about "Replacing the spools in transmission pump relief valve" on model V50D. (For Lift Truck)4. Find the Service Letter date for "Replacing the 7W1454 or 7W1455 actuator assemblies 9Y4603 throttle assembly on certain 3408". (For Power Generation)5. Find the SL date for "PS0482" for replacing failed fuel injection nozzles on certain 3208 truck engines. (For Truck Engines)6. Find how many Service Magazine articles on component code 4001 make reference to the CH65 S/N 7YC. (For Heavy Equipment)


REFERENCE: SEBD0547 - SIRS User Instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proficiency in Using Caterpillar Service Literature

EQUIPMENT REQUIRED:

None

PROCEDURE:

1. Define the below listed Service Literature Publication abbreviations and describe what each publication is for.

P.I.P. 0.T. S.I.S.

S.I.R.S. T.I.B. FIND

P.S.P. S.M.C.S.


REFERENCE:

SEBD0547 SIRS User Instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Removal and Installation of Crankshaft Seal and Wear Ring.

EQUIPMENT REQUIRED:

Seal Removal and Installation Tools Engine

PROCEDURE:

1. Remove and install seal and wear sleeve according to Special Instructions. 2. Check surfaces for cleanliness. 3. Lightly lubricate seal. 4. Use caution to prevent seal damage. 5. Check alignment to prevent damage to seal.

REFERENCE:

Service Manual Video Tape 33 – SEVV9033 (¾”) Special Instructions - SMHS7100 and SMHS8301 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Procedure to Properly Shim Idler on Low-Sprocket Machine

EQUIPMENT REQUIRED:

Idler Assembly Roller Frame

PROCEDURE:

1. See Special Instructions.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Thermistor Thermometer Group

EQUIPMENT REQUIRED:

9S9102 Thermistor Thermometer Group Hydrostatic Transmission Engine

PROCEDURE:

1. Measure ambient air temperature. 2. Measure water temperature before and after the radiator. 3. Measure oil temperature at outlet of transmission.

REFERENCE:

Special Instructions - SMHS7140 Video Tape 92 – How To Use Cooling System Diagnostic Tools Themistors SEVN9092 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Machining Powershift Transmission Clutch Housing for Oversize Rings

EQUIPMENT REQUIRED:

Lathe Worn Clutch Housing Oversize Piston Ring

PROCEDURE:

1. Install housing on fixture group. 2. Align radially and axially. 3. Machine piston ring surface to oversized dimension.

REFERENCE:

Guideline for Reusable Parts - SEBF8006 and SEBF8014 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Refacing Powershift Transmission Piston

EQUIPMENT REQUIRED:

Lathe Powershift Transmission Piston

PROCEDURE:

1. Install piston on fixture group. 2. Align radially and axially. 3. Machine face to remove wear grooves.

REFERENCE:

Guideline for Reusable Parts - SEBF8006 and SEBF8014 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Boring of Loader Lift Arm Group

EQUIPMENT REQUIRED:

Lift Arm Group Line Boring Equipment

PROCEDURE:

1. Set up tooling. 2. Bore pin locations. 3. Install sleeves or bushings if necessary.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking a Fixed Value Resistor

EQUIPMENT REQUIRED:

Multimeter Fixed Value Resistor

PROCEDURE:

1. Select proper scale.2. Attach leads correctly.3. Remove any wiring or component that may cause an inaccurate reading if

testing is done on a regulator.4. Determine value in ohms and test resistor for open and shored circuit.

REFERENCE:

Special Instructions – SEHS7734 SR4 Generator Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking a Variable Resistor (Potentiometer)

EQUIPMENT REQUIRED:

Multimeter Variable Resistor

PROCEDURE:

1. Select proper scale2. Attach leads correctly.3. Disconnect any wires that may cause an incorrect reading.4. Determine values in ohms and test resistor for open and shorted circuit.

REFERENCE:

SR4 Generator Service Manual Special Instructions – SEHS7734 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking a Capacitor EQUIPMENT REQUIRED: Multimeter Capacitor PROCEDURE:

1. Select proper scale.2. Attach leads correctly.3. Reverse Polarity.4. Determine Condition of Capacitor

REFERENCE: Service Manual SR4 Generator Service Manual Special Instructions – SEHS7734 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the Rockwell Hardness Tester

EQUIPMENT REQUIRED: Rockwell Hardness Tester Samples of Metal PROCEDURE: 1. Use spring-loaded punch, provided, to make hole in piece being tested. 2. Set magnifying glass with scale over hole. 3. Align scale on one side of the hole and read the scale where the other

side of the hole intersects the scale.

REFERENCE: PTC Data Bulletin 2112-2 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate the Use of Temperature Crayons in Measuring Weld Joint

Temperature

EQUIPMENT REQUIRED: Metal Temperature Crayon Acetylene Torch with Heating Tips PROCEDURE: 1. Heat metal. 2. Using three (3) different temperature crayons. Determine metal temperature at different distances. REFERENCE: Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate the Operation and Servicing of the Glass Cleaning Machine

EQUIPMENT REQUIRED: Several Items for Cleaning Bead Cleaning Machine PROCEDURE: 1. Demonstrate precaution to follow when using different types of metals. 2. Steam clean greasy parts first. 3. Never put wet parts in cleaner. 4. Clean valves and change the cleaning media. REFERENCE: Guideline for Reusable Parts Fundamental Skills Development Guide - SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


DEFINITION

PERFORMANCE SKILL 77 TITLE: Demonstrate Proper Use of Caterpillar Adhesives EQUIPMENT REQUIRED: 7M7260 Adhesive 5H2471 Adhesive 9S3262 Sealant Kit 5M2941 Epoxy Cement 5S1454 Sealing Compound 7F2770 Rubber Cement 4H5363 Permatex No. 1 PROCEDURE: 1. Determine what adhesive or sealant should be used. NOTE: 7M7260 - .10" gasket - final drive cover and bevel gear case 5H2471 - Bonds cork, leather or rubber to metal 9S3262 - Locks and seals nuts, bolts, screws, and studs 2. Apply adhesive or sealant for several applications. REFERENCE: Service Manual One Safe Source Book NEXG4502 - Questions & Answers about Caterpillar Adhesives, Sealants and Maintenance Products Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Tightening of Cylinder Head Bolts

EQUIPMENT REQUIRED: Engine 8T9293 Torque Wrench or 9S7353 Torque Wrench PROCEDURE: 1. Tighten cylinder head bolts according to correct sequence. REFERENCE: Service Manual Check the S.I.R.S. and Find System for the latest updates.




REVISED 2001



TITLE: Demonstrate Proper Installation of Cylinder Block Liner Insert EQUIPMENT REQUIRED: Engine Block 8S3140 Counterboring Tool Group 5P4175 Insert Tooling Group PROCEDURE: 1. Machine block. 2. Install insert and measure for correct liner projection. REFERENCE: Special Instructions - FMO55228, GMG02442 and SMHS7221 Video Tape 43 – Cylinder Block Counterboring JEGO9043 (¾”) Video Tape 47 – Cylinder Block Liner Seat Sleeving JEGO9047 (¾”) Video Tape 147 – D342 & D353 Spacer Plate Block Salvage SEVV9147 (¾”) Check S.I.R.S. and Find System for the latest updates.




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Infrared Thermometer Group\

EQUIPMENT REQUIRED: Infrared Thermometer Group Engine

PROCEDURE: 1. Properly calibrate instrument for area being tested.

2. Operate engine and record temperatures of exhaust, cooling, or hydraulic system.

3. Record your findings on worksheet #12 and attach to this form. REFERENCE: Special Instructions - SEHS8149 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:





REVISED 2001



TITLE: Demonstrate Troubleshooting the Electronic Monitoring System (EMS)

Operator Panel

EQUIPMENT REQUIRED: Machine with EMS 5P7277 Voltage Tester Digital Multimeter or Simpson 260 VOM or Equivalent 8S4627 Continuity Tester

PROCEDURE: 1. Conduct test as outlined in Service Manual.

2. If incorrect results are obtained, refer to Service Manual Troubleshooting Guide.





REVISED 2001



TITLE: Demonstrate Proper Track Adjustment of Track-Type Tractor or Loader

EQUIPMENT REQUIRED: Track-Type Tractor or Loader 8F9866 Hand Grease Gun Straight Edge or Ruler String

PROCEDURE:

1. Properly adjust both tracks of machine for both high drive and conventional machines.

REFERENCE: Service Manual Video Tape 113 – Track Adjustment Procedure SEVN9113 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Method of Lubricating Track Roller (Lifetime Lubricated) EQUIPMENT REQUIRED: Bottom Roller 5M2080 Lubricator Nozzle 5P2387 Pump Group PROCEDURE: 1. Properly fill roller. 2. Leak test using the regulated pressure method REFERENCE: Service Manual Undercarriage Recondition Bulletin - SEBF8515 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Bearing/Gear Puller Group.

EQUIPMENT REQUIRED: Shaft with Gear or Bearing 1P2321 or 1P2322 Puller

PROCEDURE: 1. Properly set up tooling. 2. Safely remove bearing or gear. 3. Safely remove a bearing cup. 4. Safely use the bearing heater. 5. Safely install a gear or bearing.

REFERENCE: Service Manual - SENR3193 Video Tape 44 – Working With Pullers SEVN9044 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal and Installation of Sprocket (Track-Type Tractor)

EQUIPMENT REQUIRED: Track-Type Tractor Tooling for Machine being used 5P3100 Pump Group (or 9S8550 or 2P5550 or 3S6224) PROCEDURE: 1. Select correct tooling from Tool Room.

2. Remove sprocket according to Service Manual procedure. Make repairs if needed.

3. Install sprocket according to Service Manual procedure. REFERENCE: Service Manual Video Tape 46 – D7F Track-Type Tractor Bearing and Sprocket Removal and Installation SEVN9046 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Installation of Piston Assembly into a Cylinder EQUIPMENT REQUIRED: Piston with Rings, attached to Connecting Rod Ring Compressor Liner or Block PROCEDURE: 1. Correctly position rings on piston. 2. Properly lubricate piston. 3. Properly prepare rod and rod bolts to protect crankshaft. 4. Install piston assembly according to Service Manual procedure. REFERENCE: Service Manual Video Tape 138 - Piston Pin Bearing Removal and Installation SEVC9138 (¾”) Lift Truck Video Tape 46 - Continental Engine Rebuild SEVV7046 (¾”)




REVISED 2001



TITLE: Demonstrate Correct Internal Linkage Adjustment Procedure on a

Hydrostatic Power Control Unit (H.P.C.U.)

EQUIPMENT REQUIRED: Hydrostatic Power Control Unit 6V2067 Underspeed Raising Tool Group 6V2155 Protractor Group 8S2328 Dial Indicator Group 6V2060 Synchronizing Adjustment Bar 6V3085 Fixture Group PROCEDURE: 1. Follow EXACT PROCEDURE as outlined in the Service Manual. REFERENCE: Service Manual - SENR2077 Video Tape 185 – Hydrostatic Loader Troubleshooting SEVN8185 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking for Air Entry into Fuel System

EQUIPMENT REQUIRED: Engine 2P8278 Tube PROCEDURE: 1. Check according to procedure in Special Instructions. REFERENCE: Service Manual Special Instructions - GMG00825 and SMHS9208 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Method of Filling Pivot Shaft Compartment on High

Drive Tractors

EQUIPMENT REQUIRED: High drive tractor with floating pivot shaft

PROCEDURE: 1. Follow procedure outlined in Specification Section of Service Manual. REFERENCE: Service Manual Maintenance Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Using the 8T5300 or 6V3100 Fuel Injection Timing Indicator EQUIPMENT REQUIRED: 8T5300 or 6V3100 Timing Indicator Engine with timing advance PROCEDURE: 1. Check for low idle timing. 2. Check for timing advance operation. 3. Record your findings on worksheet #26 and attach to this form. REFERENCE: Service Manual Video Tape 162 – Use of The 6V3100 Diesel Engine Timing Indicator SEVN9162 (½”) Special Instructions - SEHS7742 Service Magazine - 8/31/81 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking a Diode EQUIPMENT REQUIRED: Multimeter or VOM Diode Load Voltage Tester PROCEDURE:

1. Attach multimeter and record values in ohms in both directions2. Attach load tester and check for excessive leakage.3. Determine diodes condition.

REFERENCE: Service Manual Special Instruction – SEHS7734 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking an Ignition Coil EQUIPMENT REQUIRED: VOM Coil PROCEDURE: 1. Select proper ohms scale. 2. Isolate coil to insure correct reading. 3. Attach leads. Test coil for open or shorted circuit. 4. Determine if coil is within specifications. REFERENCE: Service Manual Special Instructions - SEHS7734 Flight System Instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Making Pump Isolation Test on H.P.C.U. EQUIPMENT REQUIRED: Track Type Loader with H.P.C.U. 6V4161 Hydraulic Test Group 6V4156 Transmission Test Hand Tools PROCEDURE: 1. Install blocker plates in track motor lines. 2. Performance test H.P.C.U. as outlined in Service Manual. 3. Record your findings on worksheet #28 and attach to this form.

REFERENCE: Service Manual Video Tape 186 – Hydrostatic Loader Troubleshooting II - Analyzing the Data Sheet SENR4119 - SEVN9186 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Pressure Testing Backhoe Loader Transmission EQUIPMENT REQUIRED: Caterpillar Backhoe Loader Transmission 6V4160 Transmission Test Group or Test Bench Hand Tools PROCEDURE: 1. Follow procedure outlined in Service Manual. 2. Record following pressures on Work Sheet #2 and attach to this form. A. Pump pressure B. Converter Inlet Pressure C. Converter Outlet Pressure D. Lubrication Pressure E. Forward Drive Pressure F. Reverse Drive Pressure REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 5P6590 Wiring Harness Tester

EQUIPMENT REQUIRED: Tandem Engine Scraper 5P6590 Wiring Harness Test Group PROCEDURE: 1. Follow step-by-step instructions. REFERENCE: Service Manual Special Instructions - SMHS7842 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Machine Blocking Methods EQUIPMENT REQUIRED: Machine Blocking Stands and/or Cribbing Jacks or Lifting Equipment PROCEDURE: 1. Use safety procedures as shown in videotapes or Service Manual. REFERENCE: Service Manual Video Tape 79 – Track Removal And Installation SEVN9079 (½”) Video Tape 81 – Lifting A Vehicle With Hydraulic Jack Stands SEVN9081 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Component Lifting and Blocking methods EQUIPMENT REQUIRED: Undercarriage component or Engine or Transmission Lifting Equipment Chains and/or Slings PROCEDURE:

1. Show correct procedure for lifting a component and moving to another location.2. Show correct procedure for blocking an engine, transmission or undercarriage.

3. Install engine on engine stand (Engine Rebuild only) REFERENCE: Service Manual Video Tape 57 - Hoists, Cables and Slings SEVN9057 (½”) Fundamental Skills Development Guide - SEGV2505 Special Instructions - GMGO0576 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 1P5564 Cylinder Leakage Test Group EQUIPMENT REQUIRED: Engine 1P5564 Cylinder Leakage Test Group Hand Tools PROCEDURE: 1. Follow procedure outlined in the Service Manual and Special Instruction. REFERENCE: Service Manual Special Instruction - GMGO0694 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Dial Bore Gauge EQUIPMENT REQUIRED: Cylinder Liner 1P3537 Gauge Group PROCEDURE: 1. Check calibration of gauge. 2. Check for bore size. 3. Check for bore out-of-round. 4. Check for bore taper. REFERENCE: Service Manual Special Instructions - GMGO0981 Guideline for Reusable Parts - SEBF8049 *Transmission Rebuild Specialists should use 5P2170 Dial Bore Gauge Group. Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Disassembly and Assembly and honing of a Hydraulic

Cylinder EQUIPMENT REQUIRED: Hydraulic Cylinder 1P1784 Disassemble and Assemble Stand Cylinder Honing Stand and Hones. PROCEDURE: 1. Disassemble and assemble cylinder according to procedures in Service Manual or Special Instruction. 2. Hone Cylinder according to Rebuild Process Control guidelines. REFERENCE: Service Manual Special Instruction - SMHS6672 Video Tape 77 – Reconditioning Hydraulic Cylinders SEVV9077 (¾”) Rebuild Process Control Guidelines - Hydraulic Cylinders Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 6N0087 Valve Stem Gauge EQUIPMENT REQUIRED: Several Engine Valves 6V0087 Gauge Group PROCEDURE:

1. Measure dimensions according to procedure in Guidelines for Reusable Parts.

REFERENCE: Guideline for Reusable Parts – SEBF8002 and SEBF8034 Instruction Card – SEHS7758 Check S.I.S. or S.I.R.S. and FIND for the latest updates



Signature of Supervisor ____________________ DATE__________.

REVISED 2001



TITLE: Demonstrate Use of Vibration Selector EQUIPMENT REQUIRED: Vibration Selector Generator set, truck or tractor PROCEDURE: 1. Measure amplitude as per Special Instructions. 2. Measure frequency as per Special Instructions. 3. Record results and compare to specification. 4. Record your findings on worksheet #27 and attach to this form. REFERENCE: Operation Manual for Vibration Selector Special Instructions - SEHS7914 Troubleshooting Engine Vibration in Vehicular Equipment Special Instructions - SEHS7654 Alignment - General Instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Push-Puller EQUIPMENT REQUIRED: 8B7548 Push-Puller PROCEDURE:

1. Follow safety rules.2. Properly set up tool to remove either a hear or bearing.

REFERENCE: Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Bearing Puller

EQUIPMENT REQUIRED:

5F7343 Puller Shaft with bearing installed Push-Puller or T-bar and Hydraulic Press

PROCEDURE:

1. Follow safety rules.2. Check pullers for condition.3. Properly set up tool.

REFERENCE:

Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Bearing Cup Puller EQUIPMENT REQUIRED: Bearing Cup Puller Housing with bearing race installed. PROCEDURE:

1. Follow safety rules.2. Correctly, install puller.3. Remove cup.

REFERENCE: Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Seal Removal Tools EQUIPMENT REQUIRED: 1P3075 Seal Puller Group 5P1720 Seal Pick PROCEDURE: 1. Use lip type seal puller according to Service Manual. REFERENCE: Service Manual Video Tape 44 – Working With Pullers, Torque Wrenches, Multipliers SEVN9044 (½”) Fundamental Skill Development Guide - SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED:

PROCEDURE:

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Stud Remover EQUIPMENT REQUIRED: Stud Remover Group 8S1378 Stud Remover Group - 1/4" thru 5/8" 2P5535 Stud Remover Group - 3/4" thru 7/8" - 1" 5P0250 Stud Remover Group - Larger PROCEDURE: 1. Follow instructions outlined in Special Instructions. REFERENCE: Special Instructions - SMHS8391 Fundamental Skills Development Guide - SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removing Broken Bolts Using Cutting Torch and Easy-Out

EQUIPMENT REQUIRED: 1B9925 Easy-Out Remover or Equivalent Broken off stud Drill motor and bits

Cutting Torch (Undercarriage Rebuild Technicians and Welders only) PROCEDURE: 1. Follow safety procedures. 2. Properly select drill bit size in relation to stud being removed. 3. Properly light, adjust and cut with torch REFERENCE: Fundamental Skills Development Guide - Bars and Reconditioning Tools - SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Thread Taps and Dies and Installation of a

Threaded Insert. EQUIPMENT REQUIRED: 1P3000 Rethreading Die Group 1P3020 Machine Screw Tap Group 1P3070 Tap Group 1P3050 Tap Group Tap Group Drill Press Rethread Dies Bar Stock Threaded Inserts PROCEDURE: 1. Drill pilot hole. 2. Show correct drill bit selection. 3. Exercise care in use of tap. 4. Use thread lubricant. 5. Follow safety precautions. 6. Install Threaded Insert and drive "Keys" with special tooling. REFERENCE: Fundamental Skills Development Guide Bars and Reconditioning Tools - SEGV2505 Special Instructions - SEHS8792 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 20010



TITLE: Demonstrate Installation Of Threaded Insert. EQUIPMENT REQUIRED: Threaded Inserts Thread Tap Drill Motor and Bits Tool Guide PROCEDURE:

1. Drill out damaged threads.2. Countersink hole.3. Cut new threads.4. Screw insert in slightly below surface.5. Drive “kees” down with special tool.

REFERENCE: Special Instructions – SEHS8792 Fundamental Skills Development Guide – Bars and Reconditioning Tools – SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Measuring and Adjusting Fuel Setting on a 3500

Series Engine EQUIPMENT REQUIRED: 6V3139 Tool Group 3500 Engine PROCEDURE: 1. Check fuel setting. 2. Follow procedure outlined in Service Manual under "Fuel System Testing and Adjusting". REFERENCE: 3500 Service Manual Video Tape 168 – 3500 Series Engine Unit Injector Synchronization And Adjustments SEVV9168 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Cylinder Liner Puller EQUIPMENT REQUIRED: 5P8665 Cylinder Liner Puller PROCEDURE: 1. Follow safety rules. 2. Inspect tools for correct installation. 3. Pull liner. REFERENCE: Service Manual Video Tape 138 – Piston Pin Bearing Removal & Installation and Cylinder Liner Puller Tool SEVC9138 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Honing a Cylinder Liner EQUIPMENT REQUIRED: Flex-Hone Drill Motor PROCEDURE: 1. Follow guidelines in Special Instructions. REFERENCE: Service Manual Special Instructions – SMHS7220 Service Magazine – 2/5/73 and 7/4/77 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Hydraulic System Main Relief Pressure on a Loader

EQUIPMENT REQUIRED: Wheel Loader Hydraulic Test Group Hand Tools PROCEDURE: 1. Follow procedure outlined in the appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Engine Handling Equipment. EQUIPMENT REQUIRED: 9S9060 Dual Hook Hoist 9S8500 Engine Stand Engine Block

PROCEDURE:

1. Install lifting eyes2. Use spreader bar.3. Follow safety procedures.4. Move material from one area to another.

REFERENCE: Fundamental Skills Development Guide – Lift and Block Section – SEGV2505 Special Instructions – GEGO0576 Video Tape 57 - Hoists, Cables, Slings JEGO9057 (¾”) Video Tape 58 - Roll-over Hoist JEGO9057 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates.




REVISED 2001



TITLE: Demonstrate Use of 5P6584 Timing Light EQUIPMENT REQUIRED: 5P6584 Timing Light PROCEDURE: 1. Attach battery leads to 12V source. 2. Attach secondary pickup lead on number 1 wire. 3. Aim light at timing marks found on flywheel. 4. Turn magneto or distributor to advance or retard timing - read just to

within specifications. REFERENCE: Service Manual Natural Gas Engine Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Pin Timing Fuel System to Engine EQUIPMENT REQUIRED: 3208 Engine 3306 Engine 3406 Engine 5P4203 Sleeve Metering Fuel System Field Service Tool Group PROCEDURE: 1. Time fuel system to engine. 2. Use the procedure in the Testing and Adjusting section of Service Manual. REFERENCE: 3406 Service Manual 3208 Service Manual 3306 Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Performance Test of Hydrostatic Power Control Unit

(H.P.C.U.) Using 6V3015 Test Group or Test Stand. EQUIPMENT REQUIRED: 6V3015 Test Group or Test Stand 5P3600 Flow Meter 8S4627 Circuit Tester 6V3121 Multitach Hydrostatic Power Control Unit 8N5945 Adapter Assembly for 943 PROCEDURE:

1. Install 6V3015 Test Group, 5P3600 Flow Meter, and 6V3121 Multitach Group.

2. Move "U" tube to "test" position and test brakes.3. Run performance test and record information on "Troubleshooting Data Sheet."

4. Compare information of actual results to expected results. 5. Record your findings on worksheet #28 and attach to this form. REFERENCE: Service Manual - SENR3193 Video Tape 186 – Hydrostatic Loader Troubleshooting II – Analyzing the Date Sheet SENR4119 – SEVN9186 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of Steering Clutch EQUIPMENT REQUIRED: Steering Clutch (Oil or Dry) Steering Clutch Stand

PROCEDURE: 1. Disassemble and assemble steering clutch. 2. Measure and compare stack height. 3. Follow safety procedures outlined in Service Manual. 4. Check S.I.R.S for latest updated information

REFERENCE: Service Manual Video Tape 71- Rebuilding Oil-Type Steering Clutches SEVN9071 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Rack Synchronization and Injector

Plunger Timing on a 3500 Series Engine EQUIPMENT REQUIRED: 6V3139 Tool Group 9S9082 Engine Turning Tool 3500 Engine

PROCEDURE: 1. Check injector synchronization. 2. Check injector plunger timing.

3. Follow procedure outlined in Service Manual under "Fuel System Testing and Adjusting".

REFERENCE: 3500 Service Manual Video Tape 168 – Rack Synchronization and Injector Plunger Timing on 3500 Series Engines JEGO9168 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal and Installation of a Track Group (Master Pin Type) EQUIPMENT REQUIRED: Track-Type Tractor Track Tools 5P2380 Track Tool Arrangement PROCEDURE: 1. Insure correct lubrication (pre-lube) of all parts prior to assembly. 2. Use all safety precautions when using hydraulic press. REFERENCE: Service Manual Special Instructions - SMHS6954 Video Tape 79 – Track Removal and Installation SEVN9079 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates.




REVISED 2001



TITLE: Demonstrate Removal and Installation of a Track Group (Split Master Link Type) EQUIPMENT REQUIRED: Track-Type Tractor Track Tools PROCEDURE: 1. Insure correct lubrication (pre-lube) of all parts prior to assembly. 2. Use all safety precautions. REFERENCE: Service Manual Special Instructions - SMHS8348 Video Tape 79 - Track Removal and Installation SEVN9079 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of Piston Pump EQUIPMENT REQUIRED: Piston Pump or Motor Piston Pump or Motor Tooling PROCEDURE: 1. Follow Procedure Outlined in the Service Manual REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Recovery, Recycling, and Recharging an Air Conditioner

with R-12 or R134a Refrigerant EQUIPMENT REQUIRED: Machine equipped with air conditioner Refrigerant R-12 orR134a Recovery and Recycling equipment. Leak Detection equipment A/C Certification PROCEDURE: 1. Follow all safety rules. 2. Attach low pressure and high pressure lines. 3. Recover and Recycle refrigerant from air conditioner 4. Charge air conditioner and leak test. 5. Performance test Air Conditioner, Expansion valve and Orifice tube type. REFERENCE: Service Manual Video tape, IMACA Proper use of refrigerant Recovery and recycling Equipment. Robinair 1770 Enviro-Charge Check S.I.S. or S.I.R.S. and FIND for the latest updates

Note: Completion Of This Skill Requires That The Technician Be Certified For The Servicing Of Motor Vehicle Air Conditioners. (For Information On Obtaining Certification, Contact Technical Services At 972-721-2097 – Darr Technician only)




REVISED 2001



TITLE: Demonstrate Cleaning Air Cleaner Element

EQUIPMENT REQUIRED: Dirty air cleaner element Air supply, hose and nozzle ( 30 psi Max.) Drop light. PROCEDURE:

1. Clean filter2. Check cleaner for holes.3. Check sealing ring.

REFERENCE: Service Manual Operation and Maintenance Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Bleeding Air from Distributor Type Fuel Injection System

EQUIPMENT REQUIRED:

Perkins Engine PROCEDURE: 1. Follow procedure outlined in the Service Manual. REFERENCE: Service Manual Special Instructions - SMHS9208 Lift Truck Video Tape 58 – C.A.V. Fuel Injection Pump Removal and Installation SEVV7058 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Final Drive Sprocket Bearing Adjustment

EQUIPMENT REQUIRED:

Conventional Track-Type Tractor 6V0082 Tool Group PROCEDURE: 1. Demonstrate bearing adjustment. REFERENCE: Service Manual Special Instruction - SMHS7583 Service Magazine – 10/20/80 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Hydraulic System Main Relief and Pressure Limiter

EQUIPMENT REQUIRED:

D6H or D7H Track-Type Tractor 6V4161 Hydraulic Test Group Hand Tools PROCEDURE: 1. Follow step by step procedure outlined in the Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE: Appropriate Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Adjusting Voltage Level on an Electric Set EQUIPMENT REQUIRED: Electric Set Electric Load Tach or Frequency Meter PROCEDURE: 1. Remove the access panel on the left side of the generator. Loosen the locknuts on the voltage adjustment controls. Turn voltage droop control fully counterclockwise. 2. Start engine. Increase engine speed to nameplate rating. 3. Adjust voltage level control to give nameplate rated voltage. Put normal load on the generator. Let generator warn up to normal temperature for operation. 4. Remove the load from the generator. Adjust the voltage level control if necessary. Put a normal load on the generator. Check generator voltage. If the voltage stays at nameplate rating, regulator gain control is adjusted correctly. Tighten all locknuts. 5. If generator VOLTAGE INCREASES, turn the regulator gain control a small amount counterclockwise. If generator VOLTAGE DECREASES, turn regulator gain control a small amount clockwise. Remove the load. Adjust voltage level control if necessary. 6. Put a normal load on the generator. If the voltage does not stay at nameplate rating see Step 5. If it does, tighten all locknuts and install access panel. REFERENCE: Service Manual Operation and Maintenance Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Timing Fuel Injection Pump to Perkins Engine

EQUIPMENT REQUIRED: Perkins Engine 6V2189 or 9U6188 Timing Fixture 5P4721 Tube Assembly 5P4150 Nozzle Tester

PROCEDURE: 1. Follow procedure outlined in Service Manual.

REFERENCE: Service Manual Service Letter # 5 June 1984 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring and Adjusting Fuel Setting and Hydraulic Air

Fuel Ratio Valve on a 3406B or C Engine

EQUIPMENT REQUIRED:

3406B or 3406C Engine with New Scroll Fuel System 6V6070 Tool Group 8S4627 Circuit Tester PROCEDURE:

1. Follow procedure outlined in the Service Manual or Special Instructions. REFERENCE:

Service Manual Special Instructions - SEHS8024 Video Tape 172 – Testing and Adjusting The New Scroll Fuel System SEVV9172 (¾”) Video Tape 182 – Testing and Adjusting The Hydraulic Fuel Ratio Control On “B” Series Engine SEVV9182 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Hydraulic System Pilot Pressure

EQUIPMENT REQUIRED:

Machine with pilot operated hydraulic control valve. Examples: 225, 235, 245, E180, 963, 973, 992C, D11N 6V4161 Hydraulic Test Group Hand Tools

PROCEDURE:

1. Follow procedure outlined in the appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form.

REFERENCE:

Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Measuring and Adjusting Fuel Setting on a 3300 Series Engine with New Scroll Fuel System

EQUIPMENT REQUIRED: 3304 or 3306 Engine with New Scroll Fuel System 6V2106 Tool Group 6V3075 Dial Indicator 8S4627 Circuit Tester 6V2031 Rack Position Indicator PROCEDURE: 1. Follow Directions in service manual

REFERENCE: Service Manual Fuel Setting Chart Special Instruction – SEHS8024 Check S.I.S. or S.I.R. S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Retired EQUIPMENT REQUIRED: PROCEDURE: REFERENCE: Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking SR4 Voltage Regulator

EQUIPMENT REQUIRED:

SR4 Voltage Regulator Multimeter SPST spring loaded to “OFF” switch Frequency Meter PROCEDURE:

1. Test each component with Multimeter as outlined in the Service Manual REFERENCE: Service Manual Regulator Module (Al) Test Chart (3N1480) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking a Silicone Controlled Rectifier EQUIPMENT REQUIRED: Silicone Controlled Rectifier Digital Multimeter Test Light Load Voltage Tester PROCEDURE:

1. Using test light, follow Service Manual procedure to check S.C.R. operation.2. Following Service Manual procedure using digital multimeter to check S.C.R.

for correct ohms indications.3. With load voltage tester, check S.C.R. for leakage.

REFERENCE: SR4 Generator Service Manual Flight Systems Instructions Electric Lift Truck Troubleshooting Series Part 1 – Module 5




REVISED 2001



TITLE: Demonstrate Use of a Meggar

EQUIPMENT REQUIRED:

Electric Set Meggar PROCEDURE: 1. Prepare electric set. 2. Connect meggar. 3. Administer test. 4. Record readings.

REFERENCE:

SRCR Generator Service Manual SR4 Generator Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 6V4042 Wiring Harness Tester Group

EQUIPMENT REQUIRED:

Lift Truck with EV-1 or L.D.C. Panel 6V4042 Wiring Harness Tester Group VOM PROCEDURE:

1. Install correct tooling. 2. Perform resistance test. Disconnect the battery and discharge the

capacitor or capacitors. 3. Test harness according to Special Instruction procedure. 4. Analyze test results and make recommendation for correction if needed. REFERENCE: Service Manual Special Instructions - SEHS6663 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Steering Relief Pressure

EQUIPMENT REQUIRED:

Wheel Loader Hydraulic Test Group Hand Tools PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE:





REVISED 2001



TITLE: Demonstrate Testing Rod End Tilt Relief Valves

EQUIPMENT REQUIRED:

7M1293 Adapter 5S4648 Hose 4M5317 Bushing Wheel Loader 7S8714 Pressure Gauge

PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Pressure Staging on an Early G-Series

Hydraulic Pump

EQUIPMENT REQUIRED: Early G-Series Motor Grader (Excluding 120G) Pressure Gauge (0-5000 PSI) PROCEDURE: 1. Check pressure. 2. Check signal pressure reading where staging occurs. 3. Check maximum system pressure. 4. Record your findings on worksheet #16 and attach to this form. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Determining Engine Set point RPM

EQUIPMENT REQUIRED: Multimter 6V4060 Set Point Indicator PROCEDURE: 1. Follow procedure in service manual. REFERENCE: Service Manual Special Instructions – SEHS7931 How to Use the Set Point Indicator Video Tape 174 – Proper Governor Adjustment Using the 6V4060 Set Point Indicator SEVN9174 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Head End Relief Valves for Lift Cylinder

EQUIPMENT REQUIRED: 5P47 Blocking Cover 6V4143 Coupling 6V4161 Test Group 5P4816 Pressure Gauge 8S3033 Electric Hydraulic Pump 6V3081 Hose 943, 953, 963, or 973 Track Loader PROCEDURE:

1. Follow procedure outlined in the appropriate Service Manual. 2. Record your findings on worksheet #16 and attach to this form. REFERENCE:





REVISED 2001



TITLE: Demonstrate Internal Adjustments to Sleeve Metering Fuel System EQUIPMENT REQUIRED:

3208 Sleeve Metering Fuel System 3P2200 Tool Group Fuel Setting Charts PROCEDURE: 1. Adjust cross bar. 2. Adjust sleeves of system. REFERENCE: Service Manual Special Instructions - SMHS6988 Video Tape 76 - Testing Sleeve Metering Pumps with Fuel Injection Test Bench SEVV9076 (¾”) Video Tape 103 - V-Type Sleeve Metering Fuel Pump Calibration SEVV9103 (¾”) Video Tape 104 - In-Line Sleev3e Metering Fuel System Adjustment SEVV9104 (¾”) Video Tape 131 - Sleeve Metering Fuel System Reconditioning SEVV9131 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Pin Timing Camshafts on a 3500 Series Engine

EQUIPMENT REQUIRED:

9S9082 Engine Turning Tool 9N9991 Timing Pin 3500 Engine PROCEDURE: 1. Check engine camshaft timing. 2. Follow procedure outlined in Service Manual under "Engine Timing Check". REFERENCE:

3500 Service Manual Video Tape 184 - Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proficiency in Completing a S.I.M.S., and Service Report

EQUIPMENT REQUIRED: None

PROCEDURE: Complete S.I.M.S. and Service Report using a real situation of the below listed information. Attach worksheet # 22 to this form.

DEALER INFORMATION CUSTOMER INFORMATION FAILURE INFORMATION DEALER CUSTOMER NAME VEHICLE MODELDarr Equip. Co. ABC Construction 14GADDRESS ADDRESS SERIAL NUMBERP.O. Box 540788 6789 Tenth St. 96U06585Dallas, TX. 75354-0788 Dallas, TX. 75221 HOUR METER DEALER CODE CUSTOMER COMPLAINT 37E090 hydraulic line to wheel PARTDEL. DATE OF VEHICLE lean cylinder burst Gp. Name: Leaning February 14, 1985 Wheel LinesWORK ORDER CLOSING DATE Gp. Number: 8D8600 -March 17, 1990 Sims - 3252,5057,5102,HOURS TO REPAIR ENGINE MODEL 63126.5 Hours 3306 FAILED PARTTODAY'S DATE SERIAL NUMBER Name: Hose AssemblyMarch 19, 1990 8Z22888 Number: 9D5969WORK ORDER NUMBER RIPPER MODEL PARTS REPLACEDJ1234D 14 Qty. Number Description SERIAL NUMBER 1 5P0178 Hose 39V0546 1 8S6417 Coupling A. 2 4S5414 Sleeve 1 1P9919 Coupling A. DESCRIPTION OF REPAIR Replaced hose assembly

REFERENCE: Reporting S.I.M.S. Information - SEBD0809 I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Adjusting Air Compressor Governor

EQUIPMENT REQUIRED:

Machine with Air Brakes PROCEDURE: 1. Adjust according to Service Manual procedure. 2. State air pressure specification. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Performing Cycle Times Test on a Machine Hydraulic

System.

EQUIPMENT REQUIRED:

Machine Stop Watch PROCEDURE: 1. Perform cycle times test according to Service Manual. REFERENCE: Service Manual Video Tape 156 -Hydraulic Excavator Tests SEVN9156 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Performing Cycle Times Test on G-Series Motor Grader

EQUIPMENT REQUIRED:

G-Series Motor Grader Stop Watch

PROCEDURE:

1. Perform cycle times test according to service manual.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Performing Case Drain Test on Piston Pump

EQUIPMENT REQUIRED:

Any machine with a piston pump and case drain Stop Watch PROCEDURE: 1. Perform case drain test according to Service Manual. REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking and Adjusting Pump Signal Pressures on

an Excavator

EQUIPMENT REQUIRED:

Excavator Gauges PROCEDURE: 1. Perform task according to Service Manual. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Obtaining Proper Oil Sample using the Vacuum Extraction,

Oil Valve Probe, and Drained Oil methods.

EQUIPMENT REQUIRED:

1. Compartment to be sampled 2. Sample bottles and shop labels 3. Vacuum gun and tubing PROCEDURE:

1. Bring oil in compartment to operating temperature 2. Take an oil sample by each sampling method. 3. Correctly, complete the sample labels. 4. Route samples to the Oil Lab. 5. Complete and turn in time card. REFERENCE:

Special Instructions - SEHS9043 How to take a good Oil sample - PHEP6001 How to fill out an Oil sample Label - Oil Lab Procedures Taking a sample from the drain plug - Oil Lab Procedures Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Relining Brake Shoe

EQUIPMENT REQUIRED:

Brake Shoe Lining Rivet Machine Drill Motor and Bit PROCEDURE: 1. Demonstrate removal of old lining, cleaning of brake shoe and inspection of shoe. 2. Install new lining. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluating Worn Transmission Plates and Discs

EQUIPMENT REQUIRED: Plates and Discs Guideline for Reusable Parts PROCEDURE: 1. Compare samples to guidelines and determine reusability. 2. Discs - Demonstrate knowledge of more common wear areas. 3. Plates - Demonstrate several ways to check for warp and uneven wear. REFERENCE: Guideline for Reusable Parts - SEBF8031 Lift Truck Video Tape 8 - Troubleshooting The 2-Speed Power Shift Transmission SEVV7008 (¾”) Lift Truck Video Tape 9 - Troubleshooting The 3-speed power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52 - Single Speed Power Shift Transmission Orientation, Test & Adjust SEVV7052 (¾”) Lift Truck Video Tape 53 - single Speed Power Shift Transmission Disassembly & Assembly SEVV7053 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Evaluating Sealed and Lubricated Tracks EQUIPMENT REQUIRED: Sample of S.A.L.T. components Guidelines for Reusable Parts PROCEDURE: 1. Compare samples to guidelines and determine reuse. REFERENCE: Guidelines for Reusable Parts – SEBF8022 Check S.I.S. or S.I.R.S. and FIND for the latest updates




.

REVISED 2001



TITLE: Demonstrate Evaluating Worn Pistons, Rings and Liners and Demonstrate

Honing a Cylinder Liner. EQUIPMENT REQUIRED: Samples of Pistons, Rings and Liners or Cylinders 5P3519 or 5P4812 Ring Groove Gauge 1P3537 Dial Bore Gauge Flex Hone and Drill Motor PROCEDURE: 1. Compare samples to guidelines and determine reusability. 2. Follow guidelines and Special Instructions for honing liners. 3. Record your findings on worksheet #15 and attach to this form. REFERENCE: Special Instructions - GMGO0981 Special Instructions - SMHS7220 Guideline for Reusable Parts - SEBF8049 and SEBF8068 Diagnosing Piston Ring and Liner Failure - FEG45132 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluating Worn Main and Rod Bearings

EQUIPMENT REQUIRED:

Samples of Rod and Main Bearings PROCEDURE: 1. Compare samples to guidelines and determine reusability. REFERENCE: Guidelines for Reusable Parts - SEBF8009 Engine Bearings and Crankshafts - SEBD0531 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluating Worn Valves, Valve Springs, and Checking

Valve Rotators for Correct Operation.

EQUIPMENT REQUIRED: Cylinder head with valve rotators Samples of Valves and Valve Springs 8S2263 Spring Tester 6V87 Valve Stem Gauge 5P6518 Fixture Group Tri-Square

PROCEDURE:

1. Before disassembly - mark valve and strike lightly with a soft hammer 6 or 8 times. Valve should rotate.

2. Compare valve samples to guidelines and determine reusability. 3. Measure dimensions according to procedure in guidelines for Reusable Parts REFERENCE: Service Manual Special Instructions - SMHS6998 and GMGO2591 Special Instructions - SEHS7758 Guideline for Reusable Parts - SEBF8002 & SEBF8034 Video tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluating Worn Turbocharger Parts

EQUIPMENT REQUIRED:

Turbocharger Parts 5P6518 Fixture Group PROCEDURE:

1. Compare samples to guidelines and determine reusability. 2. Record your findings on Work Sheet #35 and attach to this form REFERENCE:

Guideline for Reusable Parts - SEBF8018 Analyzing Turbocharger Failure - FEG45138 Special Instruction - SMHS6998 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Bearing Heater

EQUIPMENT REQUIRED: Bearing Heater

PROCEDURE:

1. Prepare item to be heated2. Adjust heater temperature control

CAUTION: DO NOT OVERHEAT! REFERENCE: Service Manual Fundamental Skills Development Guide – SEGV2505 –page 499 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate PROFICIENCY in using the listed Tool Groups. EQUIPMENT REQUIRED: 8T5300 or 6V3100 Timing Indicator Machine 5P3600 Hydraulic Flow Meter 6V2100 Multitach Group 6V4060 Set Point Indicator 5P4150 Nozzle Tester PROCEDURE:

1. Measure engine timing curve using the 6v3100 or 8T5300 Timing Indicator and record your findings on worksheet # 26. Perform a hydraulic pump efficiency test using the 5P3600 Hydraulic Flow Meter.2. Measure engine set point using the 6V4060 Set Point Indicator.3. Test a set of injector nozzles using the 5P4150 Nozzle Tester and record your

findings on the worksheet #18.4. Attach worksheets to this form.

REFERENCE: Timing Indicator SI – SEHS8580 Set Point Indicator SI – SEHS7931 Nozzle Tester SI – SEHS7292 Multitach SI – SEHS7807 Hydraulic Flow Meter SI – SEHS7097 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Setting Voltage Level and Voltage Gain on Working VR3

Voltage Regulator

EQUIPMENT REQUIRED:

SR-4 Generator with VR3 Regulator PROCEDURE: 1. Follow procedures in Special Instruction. REFERENCE: Special Instruction - SEHS8866 VR3 Voltage Regulator Supplement - SENR3473 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Installation of Brake Lining On Brake Band

EQUIPMENT REQUIRED:

Brake Lining Machine Brake Band and Replacement Lining PROCEDURE: 1. Demonstrate installation of lining according to Special Instructions. REFERENCE: Special Instructions - FEO12609 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Rotary Transmission Switches Using 6V4050 Shift

Analyzer

EQUIPMENT REQUIRED:

Scraper or Truck with electronic transmission control PROCEDURE:

1. Test rotary switch according to Service Manual procedure. REFERENCE:

Service Manual Special Instructions - SEHS7918 Video Tape 178 - Use of The 6V4050 Transmission Shift Analyzer SEVN9178 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Bleeding Air from Fuel Injection System

EQUIPMENT REQUIRED:

Engine PROCEDURE: 1. Eliminate air from fuel system according to Service Manual procedure. REFERENCE: Service Manual Special Instructions - SMHS9208 L & M Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Engine Pressures on Cat or Other Engines

EQUIPMENT REQUIRED:

Engine 1U5470 or 6V9450 Engine Pressure Group PROCEDURE: 1. Check fuel system pressure according to Service Manual procedure. 2. Check Engine Boost 3. Check Engine Oil Pressure 4. State findings. REFERENCE: Service Manual Fuel Setting Micro Fiche Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Engine Oil Pressure

EQUIPMENT REQUIRED: Engine Pressure Gauge PROCEDURE:

1. Check engine oil pressure according to service manual procedure. Be sure to take pressure at correct location.

REFERENCE: Service Manual OT Fuel Fiche Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 6V146 LDC Analyzer

EQUIPMENT REQUIRED:

Lift Truck with LDC Panel 6V146 LDC Analyzer PROCEDURE:

1. Install correct tooling. 2. Conduct test according to Special Instruction procedure. 3. Analyze test results and make recommendations for corrections

if needed. REFERENCE: Service Manual Special Instructions - SEHS6633 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Aftercooler for Operation

EQUIPMENT REQUIRED:

Engine with aftercooler 9S9102 Thermistor Thermometer or 1U8865 Infrared Thermometer Group PROCEDURE:

1. Determine air temperature before and after Aftercooler. 2. Determine Air Flow before and after the Aftercooler REFERENCE:

Special Instructions - SEHS8149 and SMHS7140 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Cooling System Voltage Potential

EQUIPMENT REQUIRED:

Digital Multimeter Running Engine PROCEDURE:

1. Place one probe of meter in coolant at radiator fill neck. Attach other probe to negative battery terminal.

2. Record voltage potential with the key start switch in the "off" position, with the engine cranking, and with the engine running and all electrical accessories turned "on".

REFERENCE: Service Magazine Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Valve Rotators for Correct Operation.

EQUIPMENT REQUIRED: Cylinder Head Group with valve rotators. PROCEDURE:

1. Before disassembly – mark valve and chamber – strike lightly with soft hammer 6 or 8 times. Valve should rotate. If it doesn’t rotate, attempt to rotate entire assembly by hand. If it can be rotated, then rotator is defective. Mark for replacement.

REFERENCE: Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Guidelines for Reusable Parts – SEBF8002 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Operational Check of Engine Brakesaver

EQUIPMENT REQUIRED:

Engine Equipped With Brakesaver PROCEDURE: 1. Perform Operational Check According To Service Manual. 2. State Results Of Operation Check. 3. Check 1. Pull-Down R.P.M. Check 2. Klunk Check (Check For Free Movement Of The Valve Spool) 3. Control Valve Diaphragm Using Air Pressure. REFERENCE:





REVISED 2001



TITLE: Demonstrate Exothermic Cutting

EQUIPMENT REQUIRED:

8T7792 Mini Cutting Torch or Bronco Gun

PROCEDURE:

1. Pierce a bolt or track pin lengthwise using a mini cutting torch. REFERENCE: 8T7792 Mini Torch Operating Instructions - SEHS8923 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal and Installation of Camshaft Bearings and

Evaluate Camshaft for Reusability EQUIPMENT REQUIRED: Engine Block Micrometers Camshaft Camshaft Bearings 8S2241 Camshaft Bearing Group

PROCEDURE:

1. Remove old camshaft bearings using tooling and recommended procedure outlined in Service Manual and Engine News.2. Install bearings using tooling and recommended procedures in Service Manual and Engine News.

3. Measure journal O.D. and Bearing I.D. and calculate the clearance. 4. Record your findings on worksheet #29 and attach to this form.





REVISED 2001



TITLE: Demonstrate Differential Steering Diagnostic Instrument Test

EQUIPMENT REQUIRED: Tractor with Differential Steering 1U5796 Pressure Differential Gauge Group 6V7830 Tetragauge Group 8T0853 (0-60PSI) Gauge 6V3121 Multitach Group Hand wrenches - including metric hex 8T0861 Gauge

PROCEDURE:

1. Follow instructions to determine conditions of hydraulic valves, pump and motor.

REFERENCE: Service Manual - Systems Operation Testing & Adjusting SENR3414 Video Tape 286 - Differential Steer – How It Works TEVC1286 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Installation of Fuel Injection Valve into Pre-Combustion

Chamber

EQUIPMENT REQUIRED: Cylinder Head Group Torque Wrench PROCEDURE: 1. Install nozzle properly on body. 2. Install assembly in chamber. 3. Properly torque retaining nut. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Electric Shutoff Solenoid

EQUIPMENT REQUIRED: Engine with Electric Shutoff Solenoid

PROCEDURE: 1. Measure voltage drop across solenoid. 2. Measure amp draw.





REVISED 2001



TITLE: Demonstrate Differential Steering and Operation Tests without

Instrumentation

EQUIPMENT REQUIRED: Track Type Tractor With Differential Steering Tape Measure

PROCEDURE: 1. Following the Service Manual, check linkage adjustments. 2. With engine at Max RPM, implements raised and in hold, shift to 1st

forward and full steer left. Record diameter. 3. Repeat for right turn, record diameter. 4. Repeat above test but with dozer held in full raise. Record. 5. Analyze results.

REFERENCE: Service Manual - Systems Operation Testing & Adjusting SENR3414 Video Tape 286 – Differential Steer-How It Works TEVC1286 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Troubleshooting the Electronic Traction Aid

EQUIPMENT REQUIRED: Machine equipped with electronic traction aid

PROCEDURE: 1. Follow procedure in Service Manual. REFERENCE: Service Manual Video Tape 187 -Introduction to Automatic Electronic Traction Aid SEVN9187 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly and Evaluation of a Transmission

Oil Pump

EQUIPMENT REQUIRED: Powershift Transmission Pump Hand Tools

PROCEDURE: 1. Follow instructions outlined in appropriate Service Manual.

REFERENCE: Service Manual Diagnosing Pump Failures - FEG45137 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Determining Cause for Open Fuse or Circuit Breaker

EQUIPMENT REQUIRED: Digital Multimeter Machine PROCEDURE: 1. Explain "shorts," "opens," "intermittence, short to ground." 2. Find cause for open fuse. 3. Find cause for open circuit breaker. 4. Troubleshoot for short to ground. REFERENCE: Service Manual Service Magazine Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Radiator Cap (Automotive Type) EQUIPMENT REQUIRED: Radiator Cap 9S8140 Pressure Pump or equivalent

PROCEDURE:

1. Attach pressurizing group to radiator cap.2. Specify reading obtained3. Compare with specifications and determine if cap is serviceable.

REFERENCE: Service Manual Know Your Cooling System – SEBD0518 Video Tape 96 - How to Use the Cooling System Diagnostic Tools Pressurizing Pump SEVN9096 (½”) Video tape 94 - How to Use the Cooling System Diagnostic Tools Air Flow Meter SEVN9094 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of a Powershift Transmission

Hydraulic Control

EQUIPMENT REQUIRED: Powershift Transmission Hydraulic Control Hand Tools PROCEDURE: 1. Follow instructions outlined in appropriate Service Manual. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Evaluation of Worn Torque Converter Parts EQUIPMENT REQUIRED: Service Manual PROCEDURE: 1. Compare examples to reusable guidelines. 2. Demonstrate procedure for checking stator to turbine clearance. 3. Demonstrate checking stator in impeller clearance. REFERENCE: Guideline for Reusable Parts Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of a Powershift Transmission

EQUIPMENT REQUIRED: Powershift Transmission Lifting Equipment Hand Tools PROCEDURE: 1. Follow procedure outlined in appropriate Service Manual. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Transmission, Steering, Brake

Linkage and Evaluate for Wear.

EQUIPMENT REQUIRED: Track-Type Tractor with Pedal Steering PROCEDURE: 1. Check and adjust linkage according to Service Manual. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Machining Sprocket Shaft Bore

EQUIPMENT REQUIRED: Final Drive Case Boring Bar

PROCEDURE: 1. Machine bore to accept fabricated sleeve. REFERENCE:





REVISED 2001



TITLE: Demonstrate Measuring Steering Clutch Thickness

EQUIPMENT REQUIRED: Steering Clutch Measuring Scale PROCEDURE: 1. Check clutch pack thickness. Compare with specification.





REVISED 2001



TITLE: Demonstrate Checking Steering Clutch Control Valve (Booster) Pressure

and for Correct Operation

EQUIPMENT REQUIRED: Machine (Track-Type Tractor) 5P6225 Transmission Test Group

PROCEDURE:

1. Check steering booster for operation according to Service Manual procedure.





REVISED 2001



TITLE: Demonstrate Steering Clutch Linkage Adjustment (Pedal Steer) EQUIPMENT REQUIRED:

Machine PROCEDURE:

1. Adjust linkage according to service manual procedure.2. Check proper sequence.3. Check dimensions for accuracy.

REFERENCE: Service manual – Testing and Adjusting Section Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Brake Adjustment, including linkage. (Track -Type Tractor or Track -Type Loader)

EQUIPMENT REQUIRED: Machine Track – Type Tractor or Loader

PROCEDURE: 1. Adjust brakes and brake linkage according to service manual procedure. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Black Light Leak Detection Group and Additives

EQUIPMENT REQUIRED:

1U5566 Black Light Leak Detection Group Running Engine

PROCEDURE: 1. Add recommended quantity additive to system. 2. Use black light to observe leaks or fluid transfers.

REFERENCE: Instructions in kit. Special Magazine Shop Product Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Installation of Sprocket Rim or Sprocket Adapter

EQUIPMENT REQUIRED: Replacement Sprocket Rim or Adapter Worn Sprocket

PROCEDURE: 1. Install replacement rim according to Special Instructions.

REFERENCE: Special Instruction - SEHS7750, SEHS7751,and SEHS7274 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Metal Identification

EQUIPMENT REQUIRED: Grinder Various Metal Samples Magnet

PROCEDURE: 1. Identify metal composition using the following methods: A. Appearance Test B. Magnetic Test C. Chisel Test D. Flame Test E. Spark Test

REFERENCE: Metal Identification and Welding of Steel - copy Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate 1U5803 Deutsch Connector Repair Kit

EQUIPMENT REQUIRED: Deutch connectors, used on PEEC . EUI or HEUI engines 1U5803 Deutsch Connector Repair Kit PROCEDURE: Using special tools, disassemble and assemble Deutsch connectors used on PEEC, EUI or HEUI engines. REFERENCE: Tool Guide Directions on lid of kit. Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of a Rotochamber EQUIPMENT REQUIRED: 8B7551 Bearing Puller Attachment 8B7548 Puller Assembly

PROCEDURE: 1. Follow procedures given in Service Manual SENR2107 disassembly and assembly.

REFERENCE: Service Manual - SENR7621 (631D and 637 Tractors) Service Manual - SENR2107 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Measuring Rate of Fuel Consumption with 6V7925 Fuel Rate Indicator Group or 1U5450 Fuel Flow Monitor System Group

EQUIPMENT REQUIRED: 6V7925 Fuel Rate Indicator Group or 1U5450 Fuel Flow Monitor Running Engine

PROCEDURE: 1. Measure rate of fuel consumption of Caterpillar Diesel Engine.

REFERENCE: Special Instruction - SEHS8346 Special Instruction - SEHS8874 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Articulation Joint Wear

EQUIPMENT REQUIRED: Hydraulic Jack Bearing Cup Puller Attachment "T" Bar Tooling Group

PROCEDURE: 1. Disassemble articulated joint of main frame and determine wear. 2. Compute shims needed to compensate for wear.

REFERENCE: Service Manuals - 920, 930, 980, 988 and 992 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Excavator Swing Bearing Wear

EQUIPMENT REQUIRED: Excavator 8S2328 Dial Indicator Group

PROCEDURE: 1. Properly attach dial indicator. 2. Properly position machine. 3. Record dial indicator reading. 4. Follow procedure in Service Manual.

REFERENCE: Service Manual Service Magazine June 2, 1986 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Tilting Modular Cab EQUIPMENT REQUIRED: Vehicle equipped with Rops or Modular Cab. PROCEDURE:

1. Follow step by step procedure in Special Instruction. REFERENCE: Special Instructions – SMSH7420 and SEHS6897 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Air Arc Equipment EQUIPMENT REQUIRED: "Jet-Arc" Gun or Equivalent Electrodes Air Supply NOTE: "Arcair" and "Jetair" are synonymous terms.

PROCEDURE:

1. Using a regular "DC" welder on reverse polarity, remove an old weld or prepare a joint for welding.

REFERENCE: Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Use of Cutting Torch

EQUIPMENT REQUIRED: OXY-Acetylene Set Up Cutting Torch Various Size Cutting Tips Scrap Steel of Various Thickness’

PROCEDURE: 1. Accurately cut a section of metal plate straight and at an angle.

REFERENCE: Video Tape 50 & 51 - Gas Welding Equipment, Gas Cutting Torch and Tip Care SEVN9050 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Reading Blueprint, Laying Out and Building Example

from Blueprint

EQUIPMENT REQUIRED: Electric Welder OXY - Acetylene Welding Equipment Blueprint from Tool Guide for Fabricated Tools (FT)

PROCEDURE: 1. From furnished blueprints, read, cut out and weld a fabricated tool. 2. This fabricated tool should be placed in the tool room for use.

REFERENCE: Caterpillar Tool Guide - (Contains blueprints for many special "FT" tools) Video Tape 154 - Reading Caterpillar Prints SEVN9154 (½”) Video Tape 155 - Geometric Tolerancing SEVV9155 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Automatic Gas Cutting Machine

EQUIPMENT REQUIRED: Automatic Metal Cutting Machine "C" Kater

PROCEDURE: 1. Set up "C" Kater for metal cut. 2. Adjust flame to correct intensity for metal being cut. 3. Correctly adjust "C" Kater travel speed for clean cut.

REFERENCE: Video Tape 50 & 51 - Gas Welding Equipment, Gas Cutting Torch and Tip Care SEVN9050 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Gas Welding, Using Steel and Brass Rod

EQUIPMENT REQUIRED: OXY-Acetylene Set Up Assortment of Steel Welding Rods Assortment of Brass Welding Rods

PROCEDURE: 1. Demonstrate using both steel and brass welding techniques.

REFERENCE: Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Scarifying or Gouging with Acetylene and Oxygen Torch

EQUIPMENT REQUIRED: OXY - Acetylene Set-Up "Scarifying" or Gouging Tips PROCEDURE:

1. Demonstrate removal of an old weld or preparation of a cracked joint for welding repair.

REFERENCE: Welding, Cutting & Heating Guide - Victor 2A1/77 Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate 8T2700 Blowby/Air Flow Indicator Group

EQUIPMENT REQUIRED: 8T2700 Blowby/Air Flow Indicator Group Running Engine

PROCEDURE:

1. Following the Special Instructions, evaluate engine blowby. Compare to value given in chart.2. Measure air flow through radiator as described in Special Instructions. Record results on worksheet #12 and attach to this form.

REFERENCE: Special Instruction - SEHS8712 Service Magazine July 20, 1987 "Additional Guidelines for Using the 8T2700 Blowby/Air flow Indicator Group Know Your Cooling System - SEBD0518 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate "MIG" Wire Feed Welding

EQUIPMENT REQUIRED: "MIG" Welding Machine

PROCEDURE:

1. Demonstrate use of "MIG" welding machine correctly adjusting output voltage and wire feed speed to suit material to be welded.

REFERENCE: Hobart Pocket Welding Guide - Pages 124, 125 and 126 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 9S7370 or 6V7830 Tetragauge

EQUIPMENT REQUIRED: 9S7370 or 6V7830 Tetragauge PROCEDURE: 1. Make proper connection of tetragauge. 2. Record pump pressure, relief pressure.

REFERENCE: Service Manual Special Instructions - GMG00449 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 6V4820 Adapter Group

EQUIPMENT REQUIRED: Lift Truck with EV-1 Panel 6V4820 Adapter Group

PROCEDURE:

1. Install correct tooling - WARNING: Lift the front wheels of the lift truck and put wood blocks safely under the frame so the drive wheels are free

to turn. Disconnect the battery and discharge 1 C capacitor.2. Conduct test according to Special Instruction procedure.

3. Analyze test results and make recommendations for corrections if needed.

REFERENCE: Special Instructions - SEHS6696 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Pressure Differential Gauge Group

EQUIPMENT REQUIRED: 1U5796 Pressure Differential Gauge Group Machine with Load Sensing, Pressure Compensated Hydraulic System

PROCEDURE:

1. Connect gauge group to fittings provided to measure differential pressure (Delta P).

REFERENCE: Service Manual Service Magazine May 25, 1987 - page 7 Video Tape 202 – Pressure Compensated/Load Sensing Hydraulic System SEVN9202 (½”) Special Instruction - SEHS8979 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Evaluating and Filling Lubricated Track Joint with Portable Equipment

EQUIPMENT REQUIRED: 8T3115 Portable Track Lubricator Sealed and Lubricated Track PROCEDURE: 1. Follow Special Instructions. Attach tool. Evaluate and fill joint.

REFERENCE: Service Manual Special Instruction - SMHS8557 Service Magazine 8/12/85 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Transducer to Minimize Oil Loss During Hydraulic System

Repair

EQUIPMENT REQUIRED: 5P0306 Transducer

PROCEDURE:

1. Replace hydraulic tank oil fill cap with modified cap adapted to accept 5P0306 transducer.

2. Follow instructions in Tool Guide. 3. Apply vacuum to top of hydraulic tank. 4. Disconnect pump inlet to replace pump.

REFERENCE: Service Magazine 10/12/73 page 11 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate using the 8T1000 Electronic Position Indicator

EQUIPMENT REQUIRED: 8T1000 Electronic Position Indicator 6V4060 Set Point Indicator Running Engine

PROCEDURE: 1. Follow Special Instructions. 2. Connect the electronic position indicator to fuel rack of live engine. 3. Start engine and read rack position at engine set point RPM.

REFERENCE: Special Instruction - SEHS8623 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate 6V9130 Temperature Adapter Group and 8T5334 Surface Temperature Probe

EQUIPMENT REQUIRED: 6V9130 Temperature Adapter Group 8T5334 Surface Probe 6V770 or 6V7800 Digital Multimeter PROCEDURE: 1. Attach 6V9130 temperature adapter to multimeter.

2. Following Special Instructions, read temperatures of engine block, radiator top tank, radiator bottom tank.

REFERENCE: Special Instruction - SEHS8382 LTTB 10/01/84 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Electronic Control Analyzer Programmer (ECAP) or Digital Diagnostic Tool Group (DDT).

EQUIPMENT REQUIRED: 8T8697 Electronic Control Analyzer Programmer or 8T5282 Digital Diagnostic Tool PROCEDURE:

1. Following Special Instructions, measure engine readings and make adjustments.

REFERENCE: Special Instruction - SEHS8742 Special Instruction - SEHS8747 Special Instruction - SEHS8743 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Retired

EQUIPMENT REQUIRED: PROCEDURE: REFERENCE: Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Correct Assembly of Track Roller and Idler

EQUIPMENT REQUIRED: Rollers, idlers Seal Installer

Pressing equipment Plug Installer Dial Indicator Test Group Hand Tools Test Tooling Regulated Air PROCEDURE: 1. Follow Service Manual procedures to inspect and assemble components. 2. Test for Leaks REFERENCE: Service Manual Undercarriage Reconditioning Bulletin - SEBF8515 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Rebuilt Rollers/Idlers for Oil Leaks. EQUIPMENT REQUIRED:

Rollers or Idler Testing Tool Shop Air with Pressure Regulator PROCEDURE: 1. Follow service manual procedures to check for leaks. REFERENCE: Service Manual Undercarriage Reconditioning Bulletin – SEBF8515 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001

SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 224

TITLE: Demonstrate Automatic Submerged Arc Welding

EQUIPMENT REQUIRED: Automatic Welding Equipment

PROCEDURE: 1. Follow procedures in the Undercarriage Reconditioning Guide. REFERENCE: Undercarriage Reconditioning Bulletin MP-1 SEBF8505 Undercarriage Reconditioning Bulletin MP-2 SEBF8506 Undercarriage Reconditioning Bulletin MP-3 SEBF8507 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of Curtis 1020 Power Prover

EQUIPMENT REQUIRED: Electric Lift Truck Curtis 1020 Power Prover PROCEDURE:

1. Install correct tooling.2. Conduct test according to Curtis 1020 Power Prover Instructions.3. Analyze test results and make recommendations for corrections if needed.

REFERENCE: Service Manual Curtis 1020 Power Prover Instruction Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Pulse Generator Group

EQUIPMENT REQUIRED: 8T5200 Pulse Generator Electronic Control System Requiring Speed Sensor Input 9W6370 Electronic Speed Switch Adapter

PROCEDURE: 1. Simulate speed signal to electronic control. CAUTION: Remove axles from unit PRIOR TO TEST, (if used on Electronic Shift Control.)

REFERENCE: Special Instruction - SEHS8579 Video Tape194 - Transmission Controls for the 631/637E Wheel Tractor- Scrapers SEVN9194 (½”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Repair of VE Series Electrical Connectors

EQUIPMENT REQUIRED: 6V4810 or 8T5319 Tool Group PROCEDURE:

1. Follow procedures in Special Instructions to remove and install wires in connector.

REFERENCE:

Special Instruction - SEHS8038 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Programming the ECM of the Electronic Modular Control

Panel (SR4 Generator Mounted)

EQUIPMENT REQUIRED: SR4 Generator equipped with the Electronic Modular Control Panel PROCEDURE: 1. Refer to the Shop Manual, and adjust the following set points: A. Overspeed B. Crank termination speed C. High coolant temperature shutdown

REFERENCE: Service Manual - SENR3535 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Programming the AC Meter Module (ACM) of the Electronic

Modular Control Panel (SR4 Generator Mounted)

EQUIPMENT REQUIRED: SR4 Generator equipped with the Electronic Modular Control Panel

PROCEDURE:

1. Following the Shop Manual procedures, program the ACM for voltmeter range and current transformer (CT) ratios.





REVISED 2001



TITLE: Demonstrate Troubleshooting the Electronic Neutral/Start Control

EQUIPMENT REQUIRED: Multimeter Machine equipped with the Electronic Neutral/Start Control

EXAMPLES: "E" Series Scraper, 768C, 772B, 776B, 769C, 773B, 777B, 785, 789

PROCEDURE: 1. Test and troubleshoot control. REFERENCE: Electronic Neutral/Start Control - SENR3889 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of 6V2172 Test Terminal Board

EQUIPMENT REQUIRED: Electric Lift Truck with LDC Panel 6V2172 Test Terminal Board 6V3030 VOM

PROCEDURE: 1. Install correct tooling. 2. Check power integrity to logic, according to Technical Bulletin instructions. 3. Conduct test according to Service Manual procedure. 4. Analyze test results and make recommendations for corrections.

REFERENCE: Service Manual L.T. Technical Bulletin March 1982 - Troubleshooting the LDC System Special Instructions - SMHS6662 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Use of Recommended Tool List

EQUIPMENT REQUIRED: Tool Guide Tool Listing Fiche Microfiche Reader PROCEDURE: 1. Find tools required to repair current as well as older machines.

REFERENCE: Service Manual Tool Guide - Recommended Tool List Section Tool Listing Fiche - NBFG9000 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Cold Start Heater

EQUIPMENT REQUIRED: Lift Truck with Perkins Diesel Engine Voltmeter Amp Gauge Air Regulator Valve

PROCEDURE:

1. Check cold start heater for leakage, voltage, and current draw according to Service Manual procedure.

2. Analyze test results and make recommendations for corrections, if needed.

REFERENCE: Service Manual Lift Truck Video Tape 6 - Perkins Fuel System SEVV7006 (¾”) Lift Truck Video Tape 7 - Perkins Fuel System SEVV7007 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking High Pressure Relief Valves on Hydrostatic

Transmission

EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission

PROCEDURE: 1. Install correct tooling.

2. Properly demonstrate checking high pressure relief valves on hydrostatic transmission according to Service Manual procedure.

3. Adjust pressure if necessary.

REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) L.T. Spec. Book - SENB8060 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Hydrostatic Transmission Charge

Pump Pressure Relief Valve EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic

Transmission 0-600 Pressure Gauge Tachometer

PROCEDURE: 1. Install correct tooling. 2. Properly check charge pump pressure relief valve according to Service

Manual procedure. 3. Adjust pressure if necessary. REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Hydrostatic Transmission Low Pressure

Relief Valve

EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission 0-600 Pressure Gauge Tachometer

PROCEDURE: 1. Install correct tooling.

2. Properly check low pressure relief valve according to Service Manual procedure.

3. Adjust pressure if necessary.

REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Hydrostatic Transmission Servo Cylinder

Linkage Wear

EQUIPMENT REQUIRED: Hydrostatic Transmission

PROCEDURE: 1. Drain approximately one gallon of oil from transmission, if not already drained. 2. Mark (for assembly) and remove forward and reverse servo cylinder. 3. Check for excessive linkage wear, using reusability guidelines. 4. Make recommendation for reuse or replacement.

REFERENCE: Service Manual Guideline for Reusable Parts - SEBF8026 Hydrostatic Transmission Page 35 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Hydrostatic Transmission Charge Pump Drive

EQUIPMENT REQUIRED: Hydrostatic Transmission Mirror (small one)

PROCEDURE:

1. Drain approximately two quarts of oil from transmission, if not already drained.2. Remove charge pump and check for worn tang or broken shaft on charge

pump.3. Check tang slot shaft wear using mirror and adequate lighting.4. Remove coil wire, insert screwdriver on tang slot and turn engine several

revolutions, keeping slight amount of pressure on screwdriver.5. Analyze test results and make recommendation for corrections if needed.

REFERENCE: Service Manual Guideline for Reusable Parts - SEBF8026 Hydrostatic Transmission Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of Hydrostatic Transmission High

Pressure Relief Valve EQUIPMENT REQUIRED: Hydrostatic Transmission High Pressure Relief Valve PROCEDURE:

1. Properly identify early or late style of relief valve.2. Properly disassemble and assemble high pressure relief valve according to Service Manual procedure.

REFERENCE: Service Manual Lift Truck Video Tape 4 - Rebuilding a Hydrostatic Transmission Disassembly. SEVV7004 (¾”) Lift Truck Video Tape 5 - Rebuilding a Hydrostatic Transmission Assembly SEVV7005 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of the Hydrostatic Transmission

Manifold Metering Valve

EQUIPMENT REQUIRED: Hydrostatic Transmission Manifold Metering Valve

PROCEDURE:

1. Properly disassemble and assemble manifold metering valve according to Service Manual procedure.2. Determine if valve is reusable.

Note: Use correct procedure when installing metering shaft seal.

REFERENCE: Service Manual L.T. Video Tape 4 - Rebuilding a Hydrostatic Transmission SEVV7004 (¾”) L.T. Video Tape 5 - Rebuilding a Hydrostatic Transmission SEVV7005 (¾”) L.T. Video Tape 31 - Rebuilding a Hydrostatic Transmission SEVV7031 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Adjusting Hydrostatic Transmission Control Valve

EQUIPMENT REQUIRED: Hydrostatic Transmission

PROCEDURE:

1. Follow the procedure in the Service Manual for removing centering spring end plug.2. Adjust external linkage according to Service Manual.

REFERENCE: Service Manual - SENB8055 L.T. Video Tape 31 - Rebuilding a Hydrostatic Transmission SEVV7031 (¾”) Check the S.I.R.S. and FOND for the latest updates




.

REVISED 2001



TITLE: Demonstrate Use of 1135T Curtis Tester

EQUIPMENT REQUIRED: Lift Truck with Curtis Lift Interrupter 1135T Curtis Tester PROCEDURE:

1. Install correct tooling2. Conduct test according to service manual procedure.3. Analyze test results and make recommendations and or adjust for

corrections if needed. REFERENCE: Service Manual Check the S.I.R.S. and FIND for the latest dates




REVISED 2001



TITLE: Demonstrate Using a Peak Reading Diode Block for Checking Electric

Lift Truck Transformer

EQUIPMENT REQUIRED: Electric Lift Truck Transformer Digital Multimeter Peak Reading Diode Block or Flight Sys. Tester

PROCEDURE: 1. Install correct tooling. 2. Conduct test according to Service Manual procedure. 3. Analyze test results and make recommendation for corrections if needed.

REFERENCE: Service Manual Flight Sys. Instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Governor and Carburetor Adjustment on Cat 1404 Gasoline

Engine

EQUIPMENT REQUIRED: Lift Truck with Cat 1404 Gasoline Engine 5P6585 Electrical System Analyzer PROCEDURE:

1. Properly adjust Governor and Carburetor according to Service Manual procedure.

REFERENCE: Service Manual Lift Truck Video Tape 48 - Gasoline Carburetors and Governor Adjustments SEVV7048 (¾”) Lift Truck Video Tape 55 - IMPCO LP Conversion Kit Installation SEVV7055 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Timing of Engine Gear Train

EQUIPMENT REQUIRED: Engine

PROCEDURE:

1. Demonstrate timing of valve camshaft (and fuel system camshaft if applicable) to crankshaft.

REFERENCE: Service Manual L.T. Video Tape 46 - Continental Engine Rebuild SEVV7046 (¾”)




REVISED 2001



TITLE: Demonstrate Checking Crankshaft for Reusability EQUIPMENT REQUIRED: Used Crankshaft Two 5P8637 Vee Blocks Micrometers Dial Indicator 6V6035 Hardness Tester

PROCEDURE:

1. Check for journal wear. Check for journal taper and out-of-round. Check for surface profile. Check for surface finish. Check for visible cracks. Check for crankshaft straightness. Check for crankshaft hardness.2. Compare readings with specifications found in service manual.3. Record your findings on worksheet #15 and attach to this form.

REFERENCE: Service Manual Guideline for Reusable Parts – SEBF8039, SEBF8041 and SEBF8043 Engine Bearings and Crankshafts – SEBD0531 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Vacuum on Vacuum Operated Brakes

EQUIPMENT REQUIRED: Lift Truck with Vacuum Operated Brakes 9S7370 Tetragauge 5P6582 Vacuum Pressure Gauge

PROCEDURE: 1. Properly demonstrate vacuum test according to Service Manual procedures. 2. Analyze results and make recommendations for corrections if needed. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Installation of Fuel Injection Valve on 3208 Engine

EQUIPMENT REQUIRED: Cylinder Head Group Torque Wrench

PROCEDURE: 1. Reseal injection valve according to Service Manual procedures. 2. Install injection valve properly. 3. Properly torque retaining capscrew. REFERENCE: Service Manual Video Tape 29 - Servicing the Pencil-Type Nozzle JEGO9029 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking High and Low Idle Speed on a Diesel Engine

EQUIPMENT REQUIRED: Lift Truck with Diesel Engine 6V3121 Multitach Group

PROCEDURE:

1. Install correct tooling.2. Check high and low idle speeds according to service manual procedure.3. Make adjustments if necessary.

REFERENCE: Service Manual Lift Truck Video Tape 7 – Perkins Fuel Systems SEVV7007 (¾”) Special instructions – SEHS7807 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Tilt Cylinder Alignment

EQUIPMENT REQUIRED: Lift Truck Tilt Indicator or Protractor PROCEDURE: 1. Check tilt cylinder alignment according to Service Manual procedure. 2. Make adjustments if necessary.

REFERENCE: Service Manual L.T. Video Tape 3 - Mast Testing and Adjusting SEVV7003 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Adjusting Clutch Linkage

EQUIPMENT REQUIRED: Lift Truck with Mechanical Transmission PROCEDURE: 1. Make clutch pedal adjustment according to Service Manual procedure.

REFERENCE: Service Manual I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Checking Pressures on Transmission

EQUIPMENT REQUIRED: Lift Truck with Powershift Type Transmission Six 0-300 PSI Gauges 5P6585 Electrical Analyzer or Tachometer if Gasoline or L.P. Powered 6V3121 Multitach Group if Diesel Powered PROCEDURE: 1. Install correct tooling. 2. Conduct test according to Service Manual procedure. 3. Analyze test results and make recommendation for corrections if needed. 4. Record your findings on worksheet #20 and attach to this form. REFERENCE: Service Manual Lift Truck Video Tape 8 -Troubleshooting The 2 Speed Power Shift Transmission SEVV7008 (¾”) Lift Truck Video Tape 9 - Troubleshooting The 3-speed Power Shift Transmission SEVV7009 (¾”) Lift Truck Video Tape 52 - Single Speed Power Shift Transmission Orientation, Test & Adjusting SEVV7052 (¾”) Special Instructions - SEHS7807 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of Powershift Transmission

Control Valve

EQUIPMENT REQUIRED: Control Valve 8S2263 Spring Tester

PROCEDURE:

1. Properly disassemble and assemble control valve according to Service Manual procedure.

2. Inspect springs and spool valves and make recommendations for reusability. 3. Keep work area clean.

REFERENCE: Service Manual Lift Truck Video Tape 53 – Single Speed Powershift Transmission SEVV7053 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Adjusting LP Gas Carburetor

EQUIPMENT REQUIRED: Lift Truck with LP Gas System 5P6585 Electrical Analyzer 0-30 PSI Gauge PROCEDURE: 1. Check for LP gas leaks. 2. Adjust carburetor. 3. Follow guidelines in Service Manual.

REFERENCE: Service Manual Lift Truck Video Tape 1 - LP Gas Systems Components SEVV7001 (¾”) Lift Truck Video Tape 2 - LP Gas Systems Operation and Adjustment SEVV7002 (¾”) Gas Industries - LP - Gas Carburetion Systems - CEBS0001 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Adjusting Wheel Bearing Preload

EQUIPMENT REQUIRED: Lift Truck Torque Wrench Wheel Bearing Grease Packer PROCEDURE: 1. Properly pack wheel bearings with grease. 2. Properly adjust wheel bearing preload according to Service Manual.





REVISED 2001



TITLE: Demonstrate Removing and Installing Solid Tire from Wheel Assembly

EQUIPMENT REQUIRED: Wheel Assembly Tire Tape Measure Tire Press PROCEDURE: 1. Properly press old tire from wheel assembly. 2. Use correct push plate and install new tire.

3. Make sure all items are straight and aligned correctly. Stop pressing if a bind occurs, realign and continue to press.

REFERENCE: Chicago Industrial Tire Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal and Installation of Drive Wheels

EQUIPMENT REQUIRED: 2 - 5P3045 Jack Stand 1 - 5P4194 Wheel and Hub Dolly Lift Truck

PROCEDURE: 1. Properly block lift truck. 2. Properly remove and install drive wheels. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Park Brake Adjustment

EQUIPMENT REQUIRED: Electric Lift Truck PROCEDURE:

1. Check park brake adjustment according to service manual procedure.2. Make necessary adjustments.





REVISED 2001



TITLE: Demonstrate Checking Cylinder for Wear

EQUIPMENT REQUIRED: Engine Hydraulic Cylinder 1P3537 Gauge Group Inside Micrometer Set

PROCEDURE: 1. Check inside diameter and compare to specifications. 2. Check for out-of-roundness. 3. Make recommendation for reusability. REFERENCE: Service Manual Special Instructions - GMGO0981 Guideline for Reusable Parts - SEBF8068 Fundamental Skills Development Guide - SEGV2505 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal and Installation of Steering Axle Assembly

EQUIPMENT REQUIRED: 2 - FT1222 Wheel Stand 2 - 5P6215 Stand Group Lift Truck

PROCEDURE: 1. Properly block lift truck. 2. Remove and install steer axle assembly.

REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Use of 6V3050 Gauge Set

EQUIPMENT REQUIRED: Lift Truck with Roller Type Mast 6V3050 Gauge Set 6V3051 Adapter

PROCEDURE:

1. Properly demonstrate removal, check for proper shimming, and installation of mast channels or carriage.

REFERENCE: Service Manual Lift Truck Video Tape 3 -Mast Testing and Adjusting SEVV7003 (¾”) L.T. Technical Bulletin May 7, 1980 Pages 2-4 I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Checking Lift Chain for Wear

EQUIPMENT REQUIRED: Lift Truck 6V28 Chain Wear Gauge PROCEDURE: 1. Check lift chain wear according to Service Manual procedure. 2. Make recommendation for reusability.

REFERENCE: Service Manual Special Instructions - SMHS6637 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Lift Chain Adjustment

EQUIPMENT REQUIRED: Lift Truck PROCEDURE:

1. Check lift chain tension according to Service Manual procedure. Make adjustments if necessary.

2. Check carriage height, adjust if necessary. REFERENCE: Service Manual Lift Truck Video Tape 3 - Mast Testing and Adjusting SEVV7003 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Demonstrate Removing and Installing Forks

EQUIPMENT REQUIRED:

Lift Truck With Forks

PROCEDURE:

Follow Procedure Outlined in the Service Manual

REFERENCE:





REVISED 2001


TITLE: Demonstrate Removal and Installation of Counterweight

EQUIPMENT REQUIRED: Lift Truck Lift Truck with Adequate Capacity to Lift Counterweight or Overhead Crane Lifting Eyes Chains or Slings

PROCEDURE: 1. Remove or install counterweight. 2. Secure chain or sling to lift truck to keep counterweight from sliding off forks.





REVISED 2001


TITLE: Demonstrate Control Valve Card Adjustment

EQUIPMENT REQUIRED: M-Series D STD and SA PROCEDURE: 1. Follow Service Manual procedure. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Straightening and Aligning a Beam by Heating

EQUIPMENT REQUIRED: Bent Beam OXY - Acetylene Torch Group

PROCEDURE: 1. Straighten and align beam by using heat only. 2. Follow all safety precautions.

REFERENCE: Service Manual Service Welding Guide - SEBD0512 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001

SERVICE DEPARTMENT EMPLOYEE EVALUATION GUIDE DEFINITIONPERFORMANCE SKILL 268

TITLE: Demonstrate Checking Fuel System Supply Pressure

EQUIPMENT REQUIRED: Gas or Diesel Engine Pressure Gauge PROCEDURE: 1. Check fuel system pressure according to Service Manual procedure. 2. State findings.





REVISED 2001


TITLE: Demonstrate Bleeding Air from Brake Fluid System

EQUIPMENT REQUIRED: Lift Truck

PROCEDURE: 1. Check brake pedal adjustment. 2. Bleed air from system according to Service Manual procedure. 3. Adjust brake shoes if necessary.

REFERENCE: Service Manual Lift Truck Video Tape 40 - Troubleshooting Air Brakes SEVV7040 (¾”) Lift Truck Video Tape 54 - Mechanical Brake Adjustment SEVV7054 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Installation of Valve Guide Liner.

EQUIPMENT REQUIRED: 1404 Engine Head 6V3107 Tool Kit PROCEDURE:

1. Install correct tooling2. Machine valve guide3. Install liner.

REFERENCE:





REVISED 2001


TITLE: Demonstrate Changing LP Gas Tank

EQUIPMENT REQUIRED: Lift Truck with LP Gas PROCEDURE: 1. Change LP gas tank on lift truck according to Service Manual procedure.

REFERENCE: Service Manual Lift Truck Video Tape 1 - LP Gas System – Components SEVV7001 (¾”) Gas Industries - LP - Gas Carburetion Systems CEBS0001 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Disassembly and Assembly of Impco LP Gas Converter

EQUIPMENT REQUIRED: Impco LP Gas Converter 9S8138 Pressure Gauge

PROCEDURE:

1. Properly disassemble and assemble Impco converter according to Service Manual procedure.2. Test converter after assembly.

REFERENCE: Service Manual L.T. Video Tape 41 - Rebuild Impco Converter Gas Industries - LP - Gas Carburetion Systems CEBS0001 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Checking LP Gas Fuelock Valve

EQUIPMENT REQUIRED: Electric Fuelock Valve Vacuum Fuelock Valve

PROCEDURE: 1. Check electric Fuelock valve according to Service Manual procedure. 2. Check vacuum Fuelock valve according to Service Manual procedure.

REFERENCE: Service Manual Gas Industries - LP - Gas Carburetion Systems CEBS0001 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Checking Synchromesh Transmission Shifting Linkage

EQUIPMENT REQUIRED: Lift Truck with Synchromesh Transmission

PROCEDURE: 1. Demonstrate properly checking synchromesh transmission linkage according to Service Manual procedure. 2. Adjust if necessary. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Oil Clutch Pressure

EQUIPMENT REQUIRED: Lift Truck with oil clutch 9S8138 Pressure Gauge (0-30 PSI)

PROCEDURE:

1. Demonstrate properly checking oil clutch pressure according to Service Manual procedure.2. Analyze results and make recommendation for correction if needed.

REFERENCE: Service Manual Lift Truck Video Tape 17T - Oil Clutch Transmission Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Breaker Point Ignition System Component Operation Checks

EQUIPMENT REQUIRED: Lift Truck with Breaker Point Ignition System 5P6585 Electrical System Analyzer Dwell Meter Insulated Pliers

PROCEDURE:

1. Properly demonstrate breaker point ignition component operation checks according to Service Manual procedure.2. Analyze results and make recommendation for correction if needed.

REFERENCE: Service Manual Lift Truck Video Tape 10 - Lift Truck Ignition System – Breaker Points SEVV7010 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Breakerless Induction Ignition Component Operation Checks

EQUIPMENT REQUIRED: Lift Truck with Breakerless Induction Ignition 5P6585 Electrical System Analyzer 6V3030 VOM or equivalent Insulated Pliers PROCEDURE:

1. Properly demonstrate breakerless induction ignition component operation checks according to Service Manual procedure.2. Analyze results and make recommendation for correction if needed.

REFERENCE: Service Manual Lift Truck Video Tape 11 - Lift Truck Ignition System SEVV7011 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Use of 5P6583 Compression Gauge

EQUIPMENT REQUIRED: Lift Truck with LP or Gasoline Engine 5P6583 Compression Gauge PROCEDURE:

1. Demonstrate a cylinder compression check according to Service Manual procedure.2. Analyze test results and make recommendations for correction if needed.





REVISED 2001


TITLE: Demonstrate Use of 19943 Hydraulic Hose Fitting Tool Kit

EQUIPMENT REQUIRED: 19943 Hydraulic Hose Fitting Tool Kit Swivel Fitting Hose (Size to Fit Swivel Fitting) PROCEDURE: 1. Demonstrate properly making a hydraulic hose.

REFERENCE: Service Manual Installation Instructions for Reusable Fittings - Cascade - 5210 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Seating Brushes on an Electric Motor

EQUIPMENT REQUIRED: Electric Lift Truck Drive Motor Ruler Calculator 343337 Brush Seater Stone 6V2063 Brush Seater Stone

PROCEDURE:

1. Seat brushes according to Special Instruction procedure. WARNING: When seating drive motor brushes, lift the front wheels of the lift truck, and put wood blocks safely under the frame so the drive wheels are free to turn.

2. Demonstrate projecting brush life.

REFERENCE: Service Manual Lift Truck Video Tape 51 - Brush Seating and Electric Motor P.M. SEVV7051 (¾”) Special Instructions - SMHS6589 and SMHS6605 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Air Removal from Full Free or Full Free Triple Lift Cylinder EQUIPMENT REQUIRED: Lift Truck with Full Free or Full Free Triple Lift Cylinder PROCEDURE:

1. Properly remove air from lift cylinder according to service manual procedure.





REVISED 2001


TITLE: Demonstrate Checking the Pump or Drive Motor Overtemperature

Protection Circuits on L.D.C. or M and F Series D-SA Lift Truck

EQUIPMENT REQUIRED: Lift Truck with L.D.C. Panel or M or F Series D-SA Lift Truck PROCEDURE:

1. Check the pump and drive overtemperature protection circuits according to Service Manual procedure.2. Make any repairs if necessary.3. Follow all safety precautions.

REFERENCE: Service Manual L.E.D. Troubleshooting EMS Panel Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Use of 5P5263 Seal Installation Tool Group

EQUIPMENT REQUIRED: 5P5263 Seal Installation Tool Group Hydraulic Cylinder with Teflon Seals on Piston

PROCEDURE: 1. Disassemble hydraulic cylinder. 2. Install seals according to Lift Truck Technical Bulletin procedure. 3. Assemble hydraulic cylinder.

REFERENCE: Service Manual Tool Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Neutral Adjustment on Hydrostatic Transmission Metering Valve Linkage

EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or lift truck with Hydrostatic Transmission

PROCEDURE:

1. Properly check neutral adjustment of the metering valve linkage according to Service Manual procedure.2. Make adjustments if necessary.

REFERENCE: Service Manual Lift Truck Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Neutral Adjustment of Servo Cylinders on Hydrostatic

Transmission

EQUIPMENT REQUIRED: Hydrostatic Transmission Test Stand or Lift Truck with Hydrostatic Transmission 1P7389 Servo Cylinder Adjustment Tool 0-600 PSI Gauge

PROCEDURE:

1. Install correct pressure gauge. 2. Properly adjust servo control valve and servo cylinders according to

the Service Manual procedure under Neutral Adjustments.

REFERENCE: Service Manual Lift Truck Video Tape 31 - Hydrostatic Transmission Testing and Adjusting SEVV7031 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Steering Axle Linkage Adjustment

EQUIPMENT REQUIRED: Lift Truck PROCEDURE:

1. Check steering axle stops and linkage according to Service Manual procedure.

2. Make adjustments if necessary. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Adjusting Gasoline Carburetor

EQUIPMENT REQUIRED: Lift Truck Equipped with Gasoline Carburetor 5P6585 Electrical System PROCEDURE:

1. Demonstrate adjusting gasoline carburetor according to Service Manual procedure.

REFERENCE: Service Manual Lift Truck Video Tape 48 - Gasoline Carburetors and Governor Adjustments SEVV7048 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Voltage Test on Logics

EQUIPMENT REQUIRED: Lift Truck with G.E., Sevcon, or TMC panel VOM Adequate Personnel

PROCEDURE:

1. Install correct tooling. WARNING: Lift the front of the lift truck, and put wood blocks safely under the frame so the drive wheels are free to turn. Disconnect the battery and discharge capacitor.

2. Conduct test according to Service Manual or STMG procedure. 3. Analyze test results and make recommendations for correction if needed.





REVISED 2001


TITLE: Demonstrate Use of 5P4800 Swagging Tools for Thermoplastic Hydraulic Hose

EQUIPMENT REQUIRED: 5P4800 Swagging Tool Group Thermoplastic Hose Coupling

PROCEDURE:

1. Properly demonstrate making thermoplastic hose assembly according to Special Instructions procedure.

REFERENCE: Special Instructions - SMHS6823 L.T. Video Tape 27 - Thermoplastic Hydraulic Hose for Lift Truck SEVV7027 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Adjustment of Accelerator Box Used with G.E. Panels

EQUIPMENT REQUIRED: Lift Truck with G.E. panel VOM (Analog type easier) PROCEDURE:

1. Properly check accelerator potentiometer according to service manual procedure. WARNING Disconnect the battery and discharge IC capacitor.2. Check accelerator box for proper operation of accelerator switch, !A switch, and potentiometer (especially after removing, repairing, and installing accelerator potentiometer box.)3. Adjust accelerator linkage if necessary.

REFERENCE: Service manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 4C5084 Filter Cutter Tool

EQUIPMENT REQUIRED:

4C5084 Filter Cutter Tool Used Filters (spin on type)

PROCEDURE:

Using the Filter Cutter Tool Cut Open the Filter and Examine Filter Media for Debris

REFERENCE:





REVISED 2001


TITLE: Demonstrate Wheel Angle Sensor Operation

EQUIPMENT REQUIRED: F25 or F35 Lift Truck

PROCEDURE: 1. Raise drive wheels off floor so wheels are free to turn. 2. Drive lift truck as described in Service Manual. 3. Note any differences.

REFERENCE: Service Manual Monitor - CEKL0209 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking a Zener Diode EQUIPMENT REQUIRED: Zener Diode Load Voltage Tester VOM

PROCEDURE:

1. Attach multimeter and record values in ohms in both directions.2. Attach load tester and check for correct amount of leakage through zener.3. Determine zener diode condition.

REFERENCE: Service Manual (M30B thru M100B) Flight system tester instructions LTTB – March 1982 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking an NPN Power Transistor

EQUIPMENT REQUIRED: NPN Transistor Load Voltage Tester VOM Test Light

PROCEDURE:

1. Follow service manual procedure to check T.R.N. for shorted or open circuits.2. Use test light to verify correct T.R.N. operation.3. Attach load voltage tester to T.R.N. to check for excessive leakage.

REFERENCE: Service Manual Flight system tester instructions. Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Checking Surface Temperatures

EQUIPMENT REQUIRED: Lift Truck 8T2844 Recorder Group PROCEDURE:

1. Attach appropriate temperature range recorders to several lift truck components.2. Operate truck until it reaches operating temperature.3. Check temperature recorders to verify that they are monitoring component surface temperature.

REFERENCE: LTTB - 85-02-01 Page 2 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Use of Lubrication and Maintenance Guide EQUIPMENT REQUIRED: Service Manual PROCEDURE:

1. Locate engine oil type and change recommendations.2. Locate transmission oil type and change recommendations.3. Locate procedure for removing and installing LP fuel tanks.4. Record your findings on worksheet #21 and attach to this form.

REFERENCE: Service Manual Lift Truck Video Tape 26 – How to Use Lift Truck Service Manual SEVV7026 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Adjusting Velocity Governor

EQUIPMENT REQUIRED: Lift Truck - with XNIP liter gas engine PROCEDURE: 1. Follow Service Manual procedure. Make all three adjustments to governor. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Piston to Liner and Piston to Piston Pin Matching

EQUIPMENT REQUIRED: 2.0 liter engine parts PROCEDURE:

1. Follow Service Manual procedure using charts provided to match piston pin to piston and cylinder liner to piston.

REFERENCE

Service Manual Parts Book Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Parking Brake Adjustment on T-V 50D Lift Truck EQUIPMENT REQUIRED: Lift Truck PROCEDURE:

1. Follow service manual procedure. 2. Make any needed adjustments.





REVISED 2001



TITLE: Demonstrate Using 8T900 Clamp-on Ammeter

EQUIPMENT REQUIRED: 8T900 Ammeter 6V3030 VOM Lift Truck

PROCEDURE: 1. Attach ammeter to circuit being tested. Zero meter. 2. Operate circuit. Observe amp reading.

REFERENCE: Service Manual Special Instructions - SEHS8420 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Driver Board Test on a T.M.C. Panel

EQUIPMENT REQUIRED: F30, M-F Series D STD or SA VOM PROCEDURE: 1. Follow Service Manual procedure for driver board that is being tested.




REVISED 2001


TITLE: Demonstrate Logics Potentiometer Adjustments

EQUIPMENT REQUIRED: Any Caterpillar Electric Lift Truck VOM Ammeter Current Limit Button PROCEDURE:

1. Install correct tooling. WARNING: Lift the front wheels of the lift truck, use wood blocks under mast so the drive wheels are free to turn.2. Conduct all logics potentiometer adjustments according to Service Manual procedure for lift truck being tested.

REFERENCE: Service Manual Special Instructions - SMHS7531 LTTB March 1987 Page 2 - New Electrical Control Panel LTTB 84-03-01 Current Limit Button Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Hydrostatic Transmission Field Test

EQUIPMENT REQUIRED: Lift Truck Equipped with Hydrostatic Transmission PROCEDURE: 1. Follow procedure in Service Manual.

2. Analyze test results and make recommendation for further testing if necessary.





REVISED 2001


TITLE: Demonstrate Installing Timing Chain and Tightener on an XD3P Engine

EQUIPMENT REQUIRED: XD3P Engine PROCEDURE: 1. Install timing chain and idler gear assembly as written in Service Manual. 2. Install timing chain, tensioner and adjust as needed.





REVISED 2001


TITLE: Demonstrate Checking and Adjusting Inching Pedal Adjustment

EQUIPMENT REQUIRED: T-V50D Lift Truck

PROCEDURE: 1. Follow Service Manual procedure. 2. Make any needed adjustments.





REVISED 2001


TITLE: Demonstrate Setting XD3P Oil Pump Drive Clearance

EQUIPMENT REQUIRED:

XD3P EngineFeeler GaugeTorque Wrench

PROCEDURE: 1. Follow procedure in Service Manual. 2. Make any adjustments if needed.





REVISED 2001


TITLE: Demonstrate Self and Run Time Diagnostics

EQUIPMENT REQUIRED: F30, M50D STD or M50DSA 7/16 Wrench

PROCEDURE: 1. For self diagnostics follow Service Manual procedure. 2. Run diagnostics. Occurs during normal lift truck operation.




REVISED 2001


TITLE: Demonstrate Instrument Panel Test EQUIPMENT REQUIRED: Lift Truck Equipped with 918566 or 908131 instrument panel FT1830 Test Harness PROCEDURE:

1. Test 918566 instrument panels with FT1830 test harness.2. Test 908131 instrument panels, follow procedure in service manual.

REFERENCE: Service Manual LTTB – December, 1984 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proper Adjustments of Spool Limiters

EQUIPMENT REQUIRED: Late Model M20 - MC30 Lift Truck 5P969 Ammeter Group or 5P300 Electrical Tester 0-3,000 PSI Gauge or Tetragauge

PROCEDURE: 1. Install correct tooling. 2. Check spool limiters according to Service Manual procedure. 3. Make adjustments if necessary. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Integral Breakerless Induction Ignition Component Operation Checks

EQUIPMENT REQUIRED: Lift Truck with 1404 Engine 5P6585 Electrical System Analyzer 6V3030 VOM or Equivalent PROCEDURE:

1. Properly demonstrate integral breakerless induction ignition component operation checks according to service manual procedure.

2. Analyze results and make recommendation for correction if needed. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Analyzing Engine Vibration

EQUIPMENT REQUIRED: Vibration selector Engine with vibration

PROCEDURE: 1. Demonstrate the order of a vibration. 2. Demonstrate cause of vibration. REFERENCE: Operation Manual for vibration selector Special Instruction - SEHS7914 - Troubleshooting Engine Vibration in Vehicular Equipment Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Removal and Installation of Cylinder Pack

EQUIPMENT REQUIRED: 8T0812 or 6V9448 1U6317 Bridge 1U6319 Socket PROCEDURE: 1. Remove and install cylinder liner, piston, and rod assembly in engine.

REFERENCE: Service Manual Special Instructions - SEHS8554 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Checking Electrical Relay Operation

EQUIPMENT REQUIRED: Digital Multimeter Machine with Relay

PROCEDURE: 1. Follow procedure in reference and check relay. REFERENCE: L.T. Technical Bulletin - Aug. 1988 Service Magazine - Aug. 29, 1988 Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Testing the Starter on the Engine

EQUIPMENT REQUIRED: Digital Multimeter 8T0900 Clamp-on Ammeter

PROCEDURE: 1. Follow procedure in Service Magazine.

REFERENCE: Service Magazine - May 28, 1990 Engine News - June 1990 Special Instructions - SEHS8420 and SEHS7734 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Testing Alternator/Generator Output on the Engine

EQUIPMENT REQUIRED: Digital Multimeter 8T0900 AC/DC Clamp-on Ammeter

PROCEDURE: 1. Follow procedure in Service Magazine.

REFERENCE: Service Magazine - Video Tape - Testing the Alternator - SEVC1592 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Engine Alignment with Driven Equipment

EQUIPMENT REQUIRED: Engine Generator, pump, etc. PROCEDURE: Follow Procedure Outlined In the Special Instructions and Service Manual

REFERENCE: Service Manual Special Instructions - SEHS7654, SEHS7073 and SEHS7456 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Determining Surface Finishes

EQUIPMENT REQUIRED: Surface Comparator 6V6116 PROCEDURE: Use thumbnail. REFERENCE: Guidelines to Reusable Parts - SEBF8041 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency in Using Caterpillar Applied Failure Analysis

(Engine Components)

EQUIPMENT REQUIRED: 8S2257 Loupe Small Pick (Seal Pick) Microscope (Stereo Zoom) Small Magnet Bristle Brush and Fast Drying Solvent Failed Engine Components

PROCEDURE: 1. Follow the eight steps of Applied Failure Analysis

REFERENCE: Applied Failure Analysis Course (Engine) Course Notes Applied Failure Analysis Reference Books - SEBV0544, SEBV0554, SEBV0567 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency in Using Caterpillar Applied Failure Analysis

(Drive and Hydraulic Components)

EQUIPMENT REQUIRED: 8S2257 Loupe Small Pick (Seal Pick) Microscope (Stereo Zoom) Small Magnet Bristle Brush and Fast Drying Solvent Failed Hydraulic and Drive-train Components PROCEDURE:

1. Follow the eight steps of Applied Failure Analysis as outlined in the Applied Failure Analysis Course.

REFERENCE: Applied Failure Analysis Course Notes (Drive and Hydraulic Components. Applied Failure Analysis Books - SEBV0545, SEBV0547, SEBV0549, SEBV0552, SEBV0554, SEBV0561, SEBV0662, SEBV0563, SEBV0565, SEBV0567 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency in Conducting a Machine Condition Appraisal Report (Certified Rebuild)

EQUIPMENT REQUIRED: Filter Cutter Extension Magnet CTB Kit and Handbook Hand Tools Oil Sample Kit Parts Book Borescope Inspection Group –6V7000 Product Update Record Update and Service Magazine References Replacement Filters for Power Train, Engine and Hydraulics PROCEDURE: 1. Follow the certified rebuild appraisal procedure guide. REFERENCE: Track -Type Tractor – PEEP5212 Track-Type Tractor – D8L, D9L and D10 – PEEP6209 Wheel Type Loaders – PEEP7221 Off Highway Truck & Tractors – PEE7229 Motor Grader – PEEP8201 Wheel Tractor Scraper – PEEP9211 Track – Type Loaders – PEEP7201 S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency in Performance Evaluation of "E" Series Excavator

(Advance Variable Flow Hydraulics, Microcomputer Controls and Machine Specs)

EQUIPMENT REQUIRED: Portable Hydraulic Tester - 1U9551 Photo Pickup - 6V3136 Appropriate Gauges Digital Multimeter - 6V7800 Multitach - 6V2100 Set Point Indicator - 6V4060 Cable - 6V2198 Calculator (Battery Powered) PROCEDURE: 1. Follow procedure outline in the appropriate Excavator Adjustment and Performance Test.

REFERENCE: Service Manual Updates and Service Magazine Reference Product Update Record Excavator Performance Handbook - SEBF8292-02 "E" Series Excavator Course Caterpillar Performance Handbook - SEBD0330 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proper Hazardous Waste Handling and Storage Methods

EQUIPMENT REQUIRED: none

PROCEDURE: 1. Correctly describe the main types of chemical waste originating from Darr

locations. (Waste oil, waste antifreeze, waste solvent, waste caustic, contaminated water, contaminated fuel).

2. Describe the correct locations for storage for each waste stream.a. Waste oil: Waste oil storage tankb. Waste antifreeze: Waste antifreeze tank or designated storage drum.c. Waste solvent: Safe-T-Klean vat drums.d. Waste caustic: Caustic tankse. Contaminated water: Through grease sump in steam cleaning area.f. Contaminated fuel: In designated waste fuel storage drum

3. Describe the location of each of the storage areas.4. Demonstrate knowledge of correct method for storing waste liquids

in each area.5. Explain reasons for keeping waste streams separate.6. Describe procedures for chemical spill containment.

a. Control: Eliminate the source of the spill, if possible.b. Contain: Use oil-sorb, "kitty litter", booms or dikes.c. Communicate: Notify supervisor and proper authorities if needed.d. Cordon: Keep others out of the spill area.e. Clean: Remove spill & containment materials to proper receptacle (drum,

dumpster, etc.).7. Describe locations of spill containment/clean-up equipment & supplies.

REFERENCE: Service Manual





REVISED 2001


TITLE: Demonstrate Handling and Storage of Flammable Painting Related Materials

EQUIPMENT REQUIRED: UL-approved flammable material storage locker Assorted cans of open paint (1 gallon) Assorted cans of thinner, reducer (1 quart) Assorted oily or solvent contaminated rags Transistor radio or other electrical appliance

PROCEDURE:

1. Observe "No Smoking" regulations in paint area, remove radio/appliance from work area.

2. Properly close all paint cans. 3. Properly close all other flammable material containers. 4. Store all paint and flammable containers in storage lockers. 5. Close and secure locker door. 6. Place oily/solvent rags in approved fire-retardant container.

6. Deposit paint waste/spent cleaning liquids in liquid waste material containers.

REFERENCE: Service Manual Uniform Fire Code Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Use and Care of Respiratory Protection Equipment

EQUIPMENT REQUIRED: Half-face respirator (3M/North or equivalent) Vapor cartridges and retainer

assemblies PROCEDURE:

1. Proper fit and seal check. a. Install cartridges with retainers properly. b. Properly place respirator on face.

c. Adjust head and neck straps to snugness.d. Place palms of hands over both cartridges.e. Inhale sharply - no air should get past face seal of mask or through exhaust valve.

f. Place heel of hand on exhaust valve. g. Exhale sharply - no air should pass through or around cartridges. Air may

"burp" past face seal. h. Mask is now properly fitted and sealed. 2. Cleaning and care of respirator. a. Remove mask and remove cartridges and retainers.

b. Inspect interior gasket of cartridges for wear or breaks in gasket. c. Check for presence of rubber diaphragms in both cartridge airways.

Inspect for wear/tear. d. Unsnap exhaust valve retainer cap. e. Inspect exhaust diaphragm for wear/tear.

f. With cartridges removed, wash interior of respirator with warm soapy water while checking face seal for tears. Area inside face seal should be thoroughly cleaned as well. g. Dry interior of respirator with clean dry cloth. h. Store respirator in airtight container or bag. 3. Replacement of filter cartridges. a. Anytime seal gasket is worn or torn, or b. Anytime the odor of paint or hazardous material can be smelled while the respirator is properly being worn, or c. Every 30 days, whichever comes first. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Fire Safety EQUIPMENT REQUIRED: Two properly mounted and inspected A-B-C 10 lb. fire extinguishers PROCEDURE: ALL TECHNICIANS:

1. Correctly identify exits from areas. 2. Correctly identify areas of flammable storage (this will include products as

well as waste liquids). 3. Demonstrate location and simulated use of fire extinguishers as identified on extinguisher use label. 4. Identify types of fires on which extinguishers may be used. 5. Identify situations in which an extinguisher should be used and those in

which it should not. 6. Identify proper storage areas for oily/solvent soaked rags.

PAINTERS ONLY: 1. Describe what is meant by "explosion-proof fixture". Describe the types of

equipment found in paint areas which are explosion proof, and those which are not and are prohibited.

2. Identify ways to protect extinguishers and sprinkler heads from paint overspray.

REFERENCE: Safety Manual (Darr Equipment Co. Technicians – Safety and Environmental Handbook Section 6 page 44-46) Uniform Fire Code Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proper Preparation of Surfaces for Painting

EQUIPMENT REQUIRED: Spray Gun Piece of Painted Metal Piece of Unpainted Metal

PROCEDURE: 1. Prepare painted surface for final painting. 2. Prepare unpainted metal for final painting.





REVISED 2001


TITLE: Demonstrate Proper Cleaning of Painting Equipment

EQUIPMENT REQUIRED: Spray Gun Wrenches Cleaner PROCEDURE: 1. Disassembly and assembly of spray gun. 2. Demonstrate proper method of cleaning spray gun components.

REFERENCE: Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Correctly Mixing of Paint for Spraying

EQUIPMENT REQUIRED: Shaker Paint Thinner

PROCEDURE:

1. Demonstrate mixing paint and thinner for best spray pattern and paint coverage.





REVISED 2001


DEFINITION PERFORMANCE SKILL 329 TITLE: Demonstrate Correct Painting Technique to Get Best Results

EQUIPMENT REQUIRED: Painting Equipment Machine

PROCEDURE: 1. Demonstrate painting a machine with least amount over spray and runs. REFERENCE: Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Testing an Electric Lift Truck Drive Motor with Motor Installed

in the Truck

EQUIPMENT REQUIRED: Electric Lift Truck Hand Tools Battery Charger

PROCEDURE:

1. Using the wiring diagram from the Service Manual, by pass the SCR control and run test the drive motor using the battery charger.




REVISED 2001


TITLE: Demonstrate Bench Testing an Electric Lift Truck Drive Motor

EQUIPMENT REQUIRED: Drive Motor Hand Tools Battery Charger Cables

PROCEDURE:

1. Using the wiring diagram from the Service Manual, connect cables to motor, run test motor using the battery cables.





REVISED 2001


TITLE: Demonstrate Adjusting the SCR Control Functions Using The General Electric LX Handset EQUIPMENT REQUIRED: General Electric LX Handset General Electric EV100/200LX SCR control. PROCEDURE:

1. Follow the instruction in the General Electric LX Handset instructions, and program the EX100/200LX card functions.

REFERENCE: Service Manual General Electric LX Handset instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Monitoring Systems Fault Codes Using the General Electric LX Handset EQUIPMENT REQUIRED: General Electric LX Handset General Electric Ev100/200LX SCR control

PROCEDURE: 1. Follow the instructions in the General Electric LX handset instructions. REFERENCE: Service Manual General Electric LX handset instructions Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Pressures on Transaxle EQUIPMENT REQUIRED: T50D or V50D Lift Truck 6V7835 Transmission Test Group PROCEDURE:

1. Follow the instructions in the service manual and record your findings on worksheet # 30 and attach to this form.





REVISED 2001


TITLE: Demonstrate Making Bevel Gear and Pinion Adjustments on T50D or V50D Transaxle EQUIPMENT REQUIRED: FT1923 Spanner Wrench Transaxle 8T3217 Gauge Block Hand Tools 8S2328 Dial Indicator Group PROCEDURE: 1. Follow the instructions in the service manual. REFERENCE: Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate Calculating Rated Lifting Capacity with Crane in Different

Configurations

EQUIPMENT REQUIRED: Crane Load Rating Information

PROCEDURE: 1. Determine load, which can be supported in each quadrant.

2. Calculate load capacity relative to boom length, boom radius, use of out riggers.

REFERENCE: Crane Manufactures Load Rating Information Mobile Crane Manual, Construction Safety Association of Ontario www.csao.org Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001

http://www.csao.org/


TITLE: Demonstrate Hoist Hand Signals

EQUIPMENT REQUIRED: None

PROCEDURE: 1. Demonstrate least 15 hand signals relative to crane operation.

REFERENCE: Mobile Crane Manual, Construction Safety Association of Ontario http://www.csao.org Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Wire Rope Inspection

EQUIPMENT REQUIRED: Wire Rope with Various Defects

PROCEDURE: 1. Inspect wire rope for: a. Broken wires. b. Worn or abraded wires. c. Reduction in rope diameter. d. Rope stretch. e. Corrosion. f. Insufficient lubrication. g. Crushed, flattened or jammed strands h. High stranding and unlaying. i. Bird caging. j. Kinks. k. Bulges in rope. l. Gaps or excessive clearance between strands. m. Core protrusion.

n. Heat damage, torch burns, and electric Arc strokes.o. Corroded, cracked, bent, worn and improperly applied end connections.

REFERENCE: Mobile Crane Manual, Construction Safety Association of Ontario www.csao.org Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing and Adjusting A Piston Pump and Relief Valve on

Transmission Test Stand

EQUIPMENT REQUIRED: Test Stand Piston Pump Relief Valve

PROCEDURE:

1. Demonstrate connecting components to transmission test stand.2. Perform necessary test and adjustments to assure component is operating

correctly. REFERENCE: Transmission Test Stand Manual Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Reconditioning of Hydraulic Control Valves and Tank

EQUIPMENT REQUIRED: Hydraulic Control Valve Pilot Control Valve

PROCEDURE: 1. Disassemble and assemble valve according to procedure in Service Manual. 2. Evaluate parts for reusability.





REVISED 2001


TITLE: Demonstrate Removal and Installation of Valve Guides and Valve Seat Inserts

EQUIPMENT REQUIRED: Cylinder head stand Valve seat cutting tool Valve guide press stand Cylinder head

PROCEDURE: 1. Press out and install valve guide. 2. Remove and install valve seat. 3. Cut head for valve seat installation.

REFERENCE: Special Instructions - SMHS7935 Video Tape 62 - Cylinder Head Reconditioning JEGO9062 (¾”) Video Tape 63 – Valve Grinding JEGO9063 (¾”) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Testing and Adjusting a 7 or 8-Speed Powershift

Transmission on the Test Stand

EQUIPMENT REQUIRED: Transmission Test Stand 7 or 8-Speed Powershift Transmission (not an ICM)

PROCEDURE: 1. Demonstrate connecting transmission to test stand.

2. Perform test and adjust to specifications as outlined in transmission test stand manual.

REFERENCE: Service Manual Transmission Test Stand Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Servicing Orifice Tube in Air Conditioning System EQUIPMENT REQUIRED: Machine with orifice tube system PROCEDURE:

1. Connect gauges.2. Determine system performance. Add R-12 if necessary.3. Replace orifice tube.

REFERENCE: Service Manual Air Conditioning & Heating Service Manual – SENR3334 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Air Conditioning System Evacuation and Leak Detection.

EQUIPMENT REQUIRED:

Vacuum Pump Electronic Leak Detector

PROCEDURE:

1. Purge system.2. Evacuate system.3. Vapor change system4. Check for leaks.

REFERENCE: Service Manual Air Conditioning & Heating Service Manual – SENR3334 Electronic Leak Detector – SMHS8160 or SMHS7218 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001

SERVICE DEPARTMENTEMPLOYEE EVALUATION GUIDE DEFINITION PERFORMANCE SKILL 345

TITLE: Demonstrate Replacing Air Conditioner Receiver Drier without Discharging Air Conditioning System.

EQUIPMENT REQUIRED:

Machine with quick disconnects on receiver drier.

PROCEDURE:

1. Following service manual directions, pump R-12 from old receiver drier to new receiver drier and attach now unit.

REFERENCE: Service Manual Air Conditioning & Heating Service Manual – SENR3334 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Measuring Cushion Hitch Bearing Clearances

EQUIPMENT REQUIRED: Dial Indicator or Electronic Position Indicator Magnetic Base Tractor Scraper with Cushion Hitch

PROCEDURE: 1. Measure and record clearances at the following locations. a. Front pin in bottom H-link on either side. b. Rear pin in top H-link on either side. c. Vertical pin bores for top and bottom pins. d. Front and rear horizontal hitch pins. 2. Record your findings on work sheet # 31 and attach it to this form.

REFERENCE: Service Magazine Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Judging Weld Quality Visually

EQUIPMENT REQUIRED: Defect weld samples. Weld Comparison Replica

PROCEDURE: 1. Identify weld defects type and label them. 2. Determine if a weld sample is or is not acceptable.

REFERENCE: Caterpillar Educational Products 4052 Participant Wookbook 4053 Weld Example Set (30 Pcs.) 4054 Weld Comparison Replica Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Failure Analysis of Failed Welds

EQUIPMENT REQUIRED: Failed welds Models Visual Aids (photographs)

PROCEDURE: 1. Determine cause of failure and report.

REFERENCE: Metals Handbook Volume 11, American Society for Metals Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Welding Aluminum by Stick Welding and Oxy-Acetylene

EQUIPMENT REQUIRED: Arc Welding Machine Oxy-Acetylene Torch Aluminum Welding Rods

PROCEDURE: 1. Weld aluminum using both gas welding and arch welding techniques.





REVISED 2001


TITLE: Demonstrate Salvage Weld Procedure for Cast Iron Cylinder Blocks

EQUIPMENT REQUIRED: Standard Welding Equipment

PROCEDURE:

1. Prepare and weld a fractured cast iron cylinder block or similar component, following procedures in reference material.

REFERENCE: Salvage Weld Procedure for Cast Iron Cylinder Blocks SEHS8919 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency Using a Bore Scope

EQUIPMENT REQUIRED: Bore Scope Diesel Engine PROCEDURE: 1. Remove fuel injection nozzle. 2. Inspect cylinder walls, valves etc., without disassembling engine.

REFERENCE: Operating Manual - NEHS0504 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Checking Camber on a Caterpillar Motor Grader

EQUIPMENT REQUIRED: Motor Grader Plumb Bob Ruler

PROCEDURE: 1. Follow the procedures listed in the Service Magazine.

REFERENCE: Service Manual Service Magazine June 25, 1990 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


DEFINITION

PERFORMANCE SKILL 353 TITLE: Demonstrate Proficiency in Using Engine Dynamometer

EQUIPMENT REQUIRED: Engine Engine Dynamometer

PROCEDURE: 1. Hook up engine. 2. Run engine using Caterpillar guidelines for dynamometer testing. 3. Record your findings on work sheet # 32 and attach to this form. REFERENCE: Special Instructions - GEGO1024 and SEHS7461 OT Fuel Specifications Microfiche - SEHS7357 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency in Conducting and Evaluating Cat’s Diesel Performance Analysis Report (Par Test) EQUIPMENT REQUIRED: Truck equipped with a Caterpillar Diesel Engine Truck chassis Dynamometer Hewlett-Packard model HP- 41 series calculator system or Super-Flow Unit with Personal computer-control. Personal Safety Equipment (Safety glass, ear plugs, and safety shoes) PROCEDURE:

1. Install truck on chassis dynamometer using proper safety procedures and equipment

2. Perform performance analysis test (PAR) in accordance with Caterpillar recommended procedures, either manual or computer-controlled chassis dynamometer.

3. Record you finding on PAR test and attach to this form. REFERENCE: OT Fuel Specifications Hewlett-Packard series calculator system

1. Special instruction – SEHS80252. Cat Diesel Performance Analysis Report (PAR) LEDT6099

Super-Flow computer-controlled 1. Caterpillar PAR test compute program with instruction

Check S.I.S. or S.I.R.S. and FIND for the latest updates I have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001


TITLE: Demonstrate 7X1200 EUI Timing Adapter Group on 3176 Engine

EQUIPMENT REQUIRED: 8T8697 Electronic Control Analyzer Programmer (ECAP) 7X1200 EUI Timing Adapter Group

PROCEDURE: 1. Following instructions in Service Manual, calibrate electronic injection timing.

REFERENCE: 3176 Service Manual Special Instruction - SEHS8824 and SEHS8742 Operating Manual for 7X2000 SPM - NEHS0518 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Measuring and Adjusting Fuel Setting, Injector Timing and

Injector Synchronization on 1.1 Liter Engine

EQUIPMENT REQUIRED: 1U6680 Governor and Fuel System Adjusting Tool Group

PROCEDURE:

1. Follow the steps in the "Systems Operation Testing and Adjusting" section of the Shop Manual to make these adjustments.

REFERENCE: Service Manual OT Fuel Specifications Microfiche Video Tape 574 – 1.1 Fuel System Orientation (LEVN1574) Video Tape 575 – 1.1 Fuel System Orientation (LEVN1575) Video Tape 577 – 1.1 Fuel Timing and Specification (LEVN1577) Video Tape 578 – 1.1 Fuel Setting (LEVN1578) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Testing and Adjusting ICM Powershift Transmission on a

Transmission Test Stand

EQUIPMENT REQUIRED: ICM Transmission Transmission Test Stand 1U7446 Transmission Shift Analyzer Group

PROCEDURE: 1. Determine if transmission will shift correctly. 2. Measure and analyze pressures. 3. Make appropriate adjustments.

REFERENCE: Service Manual Service Instruction - SEHS7918 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Proficiency Using Whole Numbers

EQUIPMENT REQUIRED: Pencil and paper PROCEDURE: Study material and take test, score at least 80%

REFERENCE: TPC Training System, Unit 103 "Using Mathematics in the Plant, "Lesson One". Order 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Common Fractions

EQUIPMENT REQUIRED: Pencil and paper

PROCEDURE: 1. Study material and take test. Score at least 80% REFERENCE: TPC Training System, Unit 103 "Using Mathematics in the Plant, "Lesson Two". 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Decimal Fractions

EQUIPMENT REQUIRED: Pencil and paper

PROCEDURE: 1. Study material and take test. Score at least 80%. REFERENCE: TPC Training System, Unit 103 "Using Mathematics in the Plant," Lesson Three. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Ratios and Proportions EQUIPMENT REQUIRED: Pencil and Paper Calculator (optional) PROCEDURE: 1. Study material and take test. Score at least 80% REFERENCE: TPC Training Systems, Unit 103 “Using Mathematics in the Plant” Lesson Four. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Simple Geometric Principles

EQUIPMENT REQUIRED: Pencil and Paper Straight Edge Compass PROCEDURE: 1. Study material and take test. Score at least 80%

REFERENCE: TPC Training Systems, Unit 103 “Using Mathematics in the Plant,” Lesson Seven 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Simple Algebra

EQUIPMENT REQUIRED: Pencil and Paper

PROCEDURE: 1. Study material and take test. Score at least 80%. REFERENCE: TPC Training System, Unit 103 “Using Mathematics in the Plant, Lesson eight. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency Using Formulas

EQUIPMENT REQUIRED: Pencil and paper PROCEDURE: 1. Study material and take test. Score at least 80%. REFERENCE: TPC Training System, Unit 103 "Using Mathematics in the Plant," Lesson Nine. 1-800-837-8872 Ext. 4060 USA or www.tpctraining.com




REVISED 2001


TITLE: Demonstrate Proficiency by Completing Applied Electricity Course

EQUIPMENT REQUIRED: VCR Six video tapes PROCEDURE: 1. Watch video tapes. 2. Read Manual. 3. Work problems. 4. Take test. Must score 90% or better. REFERENCE: A Study Guide to Applied Electricity - Tel-Train (Out side of Darr) www.Telatrain.com or 1-800-251-6018 USA




REVISED 2001

http://www.Telatrain.com/


TITLE: Instruct Visual Inspection of Welds to Those Technicians Who Need Skill #347.

EQUIPMENT REQUIRED: Defective Weld Samples Weld Comparison Replica

PROCEDURE:

1. Instruct types of weld defects, causes of these defects, and how to correct or avoid.

REFERENCE: Caterpillar Education Products 4051 Instructor Guide 4052 Participant Work Book 4053 Weld Example Set (32 pcs.) 4054 Weld Comparison Replica Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Instruct Hoist Hand Signals to Those Technicians Who Need Skill #337.

EQUIPMENT REQUIRED: Visual aids PROCEDURE:

1. Instruct Technicians who need skill #337 the proper communication procedures between crane operator and assisting personnel.

REFERENCE: Mobile Crane Manual, Construction Safety Association of Ontario For information out side of Darr www.csao.org




REVISED 2001



TITLE: Instruct Wire Rope Inspection to Those Technicians Who Need Skill #338.

EQUIPMENT REQUIRED: Wire rope with different defects

PROCEDURE:

1. Instruct other Technicians who need Skill #338 the proper inspection of wire rope or cable.

REFERENCE: Mobile Crane Manual, Construction Safety Association of Ontario For information out side of Darr http://www.csao.org




REVISED 2001



TITLE: Instruct Fire Safety to Those Technicians Who Need Skill #325

EQUIPMENT REQUIRED:

Two properly mounted and inspected A-B-C 10 lb. Fire Extinguishers

PROCEDURE:1. Describe what is meant by "explosion-proof fixture". Describe the types of

equipment found in paint areas which are explosion proof and those which are and are not prohibited.

2. Correctly identify exits from any work area. 3. Correctly identify areas of flammable storage (this will include products as well as waste liquids). 4. Demonstrate location and simulated use of fire extinguishers as identified on

extinguisher use label. 5. Identify types of fires on which extinguishers may be used. (on label of

extinguisher) 4. Identify situations in which an extinguisher should or should not be used. (only

In incipient (beginning) stage of fire 7. Identify proper storage areas for oily/solvent soaked rags. 8. Identify ways to protect extinguishers and sprinkler heads for paint overspray. 9. Properly explain how to summon emergency fire response to work area.

10. Indicate proper storage areas and locations for flammable materials in work area (paint cabinets, acetylene, LP-gas, etc.) 11. Correctly identify no smoking areas in work place. Explain why these areas

are designated as no smoking areas.

REFERENCE: Safety Manual




REVISED 2001


TITLE: Instruct Use and Care of Respiratory Protection Equipment to Those

Technicians Who Need Skill #324.

EQUIPMENT REQUIRED: Half-face respirator (3M/North or equivalent) Vapor cartridges and retainer assemblies

PROCEDURE: 1. Proper fit and seal check. a. Install cartridges with retainers properly. b. Properly place respirator on face. c. Adjust head and neck straps to snugness. d. Place palms of hands over both cartridges. e. Inhale sharply - no air should get past face seal of mask or through exhaust

valve. f. Place heel of hand on exhaust valve. g. Exhale sharply - no air should pass through or around cartridges. Air may

"burp" past face seal. h. Mask is now properly fitted and sealed. 2. Cleaning and care of respirator. a. Remove mask and remove cartridges and retainers. b. Inspect interior gasket of cartridges for wear or breaks in gasket. c. Check for presence of rubber diaphragms in both cartridge airways. Inspect

for wear/tear. d. Unsnap exhaust valve retainer cap. e. Inspect exhaust diaphragm for wear/tear. f. With cartridges removed, wash interior of respirator with warm soapy water

while checking face seal for tears. Area inside face seal should be thoroughly cleaned as well.

g. Dry interior of respirator with clean dry cloth. h. Store respirator in airtight container or bag. 3. Replacement of filter cartridges. a. Anytime seal gasket is worn or torn, or b. Anytime the odor of paint or hazardous material can be smelled while the

respirator is properly being worn, or c. Every 30 days, whichever comes first. REFERENCE: Safety Manual




REVISED 2001


TITLE: Instruct Handling and Storage of Flammable Painting Related Materials

to Those Technicians Who Need Skill #323.

EQUIPMENT REQUIRED: UL-approved flammable material storage locker Assorted cans of open paint Assorted cans of thinner, reducer Assorted oily or solvent contaminated rags Transistor radio or other electrical appliance

PROCEDURE:

1. Observe "No Smoking" regulations in paint area, remove radio/appliance from work area.

2. Properly close all paint cans. 3. Properly close all other flammable material containers. 4. Store all paint and flammable containers in storage lockers. 5. Close and secure locker door. 6. Place oily/solvent rags in approved fire-retardant container. 7. Deposit paint waste/spent cleaning liquids in liquid waste material containers.

REFERENCE: Safety Manual Uniform Fire Code




REVISED 2001


TITLE: Instruct Proper Hazardous Waste Handling and Storage Methods to Those

Technicians Who Need Skill #322. EQUIPMENT REQUIRED: none PROCEDURE: 1. Correctly describe the main types of chemical waste originating from Darr locations. (Waste oil, waste antifreeze, waste solvent, waste caustic, contaminated water, contaminated fuel). 2. Describe the correct locations for storage for each waste stream. a. Waste oil: Waste oil storage tank b. Waste antifreeze: Waste antifreeze tank or designated storage drum. c. Waste paint in designated paint storage drums. d. Waste caustic: Caustic tanks e. Contaminated water: Through grease sump in steam cleaning area. f. Contaminated fuel: In designated waste fuel storage drum 3. Describe the location of each of the storage areas.

4. Demonstrate knowledge of correct method for storing waste liquids in each area.

5. Explain reasons for keeping waste streams separate. 6. Describe procedures for chemical spill containment. a. Control: Eliminate the source of the spill, if possible. b. Contain: Use oil-sorb, "kitty litter", booms or dikes. c. Communicate: Notify supervisor and proper authorities if needed. d. Cordon: Keep others out of the spill area. e. Clean: Remove spill & containment materials to proper receptacle (drum, dumpster, etc.). 7. Describe locations of spill containment/clean-up equipment & supplies. REFERENCE: Safety Manual




REVISED 2001



TITLE: Demonstrate Propeller Pitch Measurement

EQUIPMENT REQUIRED:

8T5322 Pitchometer or equivalentMarine Propeller, installed

PROCEDURE:

1. Follow special instructions, measure propeller pitch

REFERENCE:

Special Instructions - SEHS8643Check S.I.S. or S.I.R.S. and FIND for the latest updates.




REVISED 2001



TITLE: Demonstrate Testing Unit Injector

EQUIPMENT REQUIRED:

Unit Injector for 1.1 L, 1.7 L, or 3500 Engine 1U6661 Unit Injector Tester or 6V4022 Injector Tester

PROCEDURE:

1. Select the proper holders and adapters and test Unit Injector according to instructions.

2. Record your findings on work sheet #18 and attach it to this form

REFERENCE:

Service Manual Special Instructions SEHS8867 Special Instructions SEHS8884 Special Instructions SEHS7788 Check S.I.S. or S.I.R.S. and FIND for the latest updates.




REVISED 2001



TITLE: Demonstrate Proper Adjustment of a Pull Type Clutch and Clutch Brake

EQUIPMENT REQUIRED:

Truck with a Pull Type Clutch Pull Type Clutch Adjusting Tool Hand Tools

PROCEDURE:

1. Adjust the Clutch Linkage and Clutch Brake according to Manufactures Specifications

2. Adjust the Clutch according to Manufactures Specifications.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Tilting Truck Cab to the 90 degree Breakover Position

EQUIPMENT REQUIRED:

Cabover Truck Hand Tools Safety Brackets

PROCEDURE:

1. Tilt Cab for Engine Removal following the instructions outlined in the Trucks Service Manual 2. Make Sure All Safety Precautions are Followed

REFERENCE:

Service Manual for the Truck being used. Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Making Jake Brake Adjustments

EQUIPMENT REQUIRED:

Engine Equipped with Jake Brake Hand tools Feeler gauge 9S9082 engine turning tool

PROCEDURE:

1. Follow procedure outlined in the service manual.

REFERENCE:

Service manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal, Installation and Calibration of all Electronic Sensors on P.E.E.C Engine

EQUIPMENT REQUIRED:

P.E.E.C. Engine Hand Tools

PROCEDURE:

1. Follow Procedure Outlined in the Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Making Unit Injector Height Adjustment on 3406E Engine

EQUIPMENT REQUIRED:

3406E Engine Hand Tools 9U7227 Injector Height Gauge

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Removal and Installation of Injection Sleeves on 1.1 L or 1.7 L Engines, using the 4C4462 Tool Group

EQUIPMENT REQUIRED:

1.1 L or 1.7 L Engine Hand Tools 4C4462 Tool Group

PROCEDURE:

1. Remove and Install Injector Sleeve Following the Procedure Outlined in the Special Instructions and Service Manual

REFERENCE:

Service Manual Special Instructions SEHS9120 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removing and Installing Injector Sleeves on 3406E using the 9U6891 Tool Group

EQUIPMENT REQUIRED:

3406E Engine 9U6891 Tool Group

PROCEDURE:

1. Remove and Install Injector Sleeves Following the Procedure Outlined in the Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Using the 4C6761 Component Tester (Handyman Flight Systems Component Tester)

EQUIPMENT REQUIRED:

Electrical Components: 1. Diode 2. Silicone Controlled Rectifier (SCR) 3. Zener Diode 4. Capacitor

PROCEDURE:

1. Follow the Procedure Outlined in the Handyman Operators Manual

REFERENCE:

Handyman Model 269 Operators Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate 3500 Gas Engine Set Up, including, "A" Regulator, Governor Linkage, Carburetor and Waste Gate adjustment.

EQUIPMENT REQUIRED:

3500 Gas Engine Protractor 6V9450 Engine Pressure Group 8T5160 Regulator Adjusting Tool Kit Water Manometer Fuel Setting Micro Fiche 6V2100 Multitach Group Exhaust Gas Analyzer

PROCEDURE:

1. Follow Procedures Outlined in the Service Manual and Special Instructions and Gas Engine Performance book.

REFERENCE:

Service Manual Special Instructions - SEHS8524 Special Instructions - SEHS7807 Fuel Setting Micro Fiche Gas Engine Performance - LEBQ2023 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing Fuel Supply System using the FT1996 Low Fuel Pressure Test Kit

EQUIPMENT REQUIRED:

Truck with 3300 or 3400 Engine Hand Tools FT1996 Low Fuel Pressure Test Kit

PROCEDURE:

1. Test Fuel Supply System as Outlined in the Truck Performance diagnostic Guide and Record your findings on Work Sheet #34 and attach to this form

REFERENCE: Truck Engine Performance Diagnostic Guide SEBD0808 Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Demonstrate Installing a Magneto and Setting the Timing on a Gas Engine

EQUIPMENT REQUIRED: Gas Engine 9S9082 Engine Turning Tool 5P6584 Timing Light or 6V3100 or 8T5300 Timing Indicator 6V9060 Spark Timing Adapter Group

PROCEDURE: 1. Install the Magneto and check the Engine Timing as outlined in the Service

Manual. REFERENCE: Service Manual Special Instructions - SEHS8580 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001


TITLE: Successfully Complete a Supervision/Management Course at a Local

Community College

EQUIPMENT REQUIRED: None PROCEDURE: None REFERENCE: See Service Development Department For Details




REVISED 2001


TITLE: Instruct, Observe and Certify at Least 10 Skills for Junior Technicians

EQUIPMENT REQUIRED: None PROCEDURE: Follow Procedures and Instructions Outlined in the Employee Evaluation Guide

REFERENCE: Employee Evaluation Guide




REVISED 2001


TITLE: Demonstrate Opening and Closing a Work Order

EQUIPMENT REQUIRED: Company Computer Terminal

PROCEDURE: 1. Follow Procedure Outlined in the Caterpillar Dealer Information Systems

(C.D.I.S.) Manual

REFERENCE: Caterpillar Dealer Information Systems (C.D.I.S.) Manual.




REVISED 2001


TITLE: Demonstrate Rolling Tracks For Transportation

EQUIPMENT REQUIRED:

Track Coiling Clamps Grove Crane or equivalent

PROCEDURE:

1. Follow the procedure outline in the Undercarriage Rebuild Guide

REFERENCE:

Undercarriage Rebuild Guide bulletin MP 13 – SEBF8557 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate the Proper Installation of a Duo-Cone Seal

EQUIPMENT REQUIRED:

Hand Tools Duo-Cone Installation Tools Machine with Duo-Cone Seals

PROCEDURE:

1. Follow the Procedure Outlined in the Service Manual and Special Instructions.

REFERENCE:

Tool Chart SEHS8484 Special Instructions SEHS8876 Special Instructions SEHS8364 Service Manual Service Magazine Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module One: Course Introduction

EQUIPMENT REQUIRED:

Interactive Video Computer Video Disc Fundamentals of Electrical Systems

PROCEDURE:

1. Follow Computer On Screen Directions

REFERENCE:

Caterpillar Multimedia Products TEMV9002 Check S.I.S. or S.I.R.S. and FIND for the latest updates

have studied the listed material and have demonstrated the skill listed on this sheet. _____________________ (Signature & Emp #).



REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Two: Applying Basic Electrical Concepts

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Three: Using Diagnostic Tools

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Four: Trouble Shooting Basics

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Five: The Caterpillar Lighting System

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Six: The Caterpillar Starting System

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE: Caterpillar Multimedia Products TEMV9002 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Electrical Systems Module Seven: The Caterpillar Charging System

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module One: Course Introduction

EQUIPMENT REQUIRED:

Interactive Video Computer Video Disc Fundamentals of Mobile Hydraulics

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Compete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module two: basic Hydraulic Concepts

EQUIPMENT REQUIRED:

Interactive Video Computer Video disc fundamentals of Mobile Hydraulics

PROCEDURE:

Follow Computer On Screen Directions

REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Three: Components

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Four: Schematics

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Mobile Hydraulics Module Five: Systems

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module One: Introduction

EQUIPMENT REQUIRED:

Interactive Video Computer Video Disc Fundamentals of Applied Failure Analysis

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Two: Fundamentals of Metallurgy

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Three: Analyzing Fractures

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Four: Analyzing Wear

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Five: Visual Examination

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Video Self-Instruction Course, Fundamentals of Applied Failure Analysis Module Six: Managing Failure Analysis

EQUIPMENT REQUIRED:


PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Adjustment of a P.T.O. Clutch on a RR250 or SS250.

EQUIPMENT REQUIRED:

RR250 or SS250 Spring Scale Hand Tools

PROCEDURE:

1. Follow Procedure Outlined in the Service Manual and Service Magazine

REFERENCE:

Service Manual Service Magazine 9-12-88 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing, Adjusting and Trouble Shooting Load Control (Feet Per Minute Control) on RR/SS or Compactor

EQUIPMENT REQUIRED:

Machine With Load Controller (Feet Per Minute Control) Pulse Generator Digital Multimeter Multitach Hand Tools

PROCEDURE:

1. Follow the Procedure Outlined in the Service Manual and Service Magazine.

REFERENCE:

Service Manual Service Magazine - 2-26-90 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Frequency of Vibration on Vibratory Compactor

EQUIPMENT REQUIRED:

Vibratory Compactor 773904 Tach or 8C1869 Tach 6V2100 Multitach

PROCEDURE:

1. Follow the Procedure Outlined in the Service Manual

REFERENCE: Service Manual Service Magazine 6-15-92 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking and Adjusting Vibration/Propulsion Pump Charge Pressure

EQUIPMENT REQUIRED:

Vibratory Compactor 6V3121 Multitach 1U8865 Infrared Thermometer 0-300 psi Gauge 0-580 psi Gauge

PROCEDURE:


REFERENCE:

Service Manual Special Instructions - SEHS7807 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Testing and Adjusting the Main Relief Valve Pressure on Two Pump Vibratory Compactor

EQUIPMENT REQUIRED:

Vibratory Compactor Two 0-9000 psi Gauges 4C4892 ORFS Fitting Group

PROCEDURE:

1. Follow the Procedure Outlined in the Service Manual





REVISED 2001



TITLE: Demonstrate Setup, Testing, Adjusting and Calibration of Automatic Grade/Depth Control on Paving Products.

EQUIPMENT REQUIRED:

Paving Equipment With Grade/Depth Control Hand Tools

PROCEDURE:


REFERENCE:

Service Manual Service Magazine 10-4-93 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Transmission Solenoids

EQUIPMENT REQUIRED:

TelehandlerVOM

PROCEDURE:

1. Locate and expose Solenoid Bank.2. Without starting engine , turn Key Switch to the ON Position.3. Test each Solenoid for Voltage in Neutral, all Forward Speeds, and all

Reverse Speeds.4. Turn Key Switch Off, and properly test each Solenoid Coil's resistance.5. Note differences in Voltages and Resistance’s between Solenoids.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Hydraulic System Solenoids.

EQUIPMENT REQUIRED:

Telehandler VOM

PROCEDURE:

1. Locate all Hydraulic Solenoids and name the Function it controls.2. Without starting engine, turn Key Switch to the ON Position.

3. Using each Solenoids corresponding switch activate and Test each Solenoid for Voltage.4. Turn Key Switch Off, and properly test each Solenoid Coil's resistance.5. Note differences in Voltages and Resistance’s between Solenoids.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Hydraulic System Pressures.

EQUIPMENT REQUIRED:

TelehandlerHydraulic Pressure Gages

PROCEDURE:

Following Service Manual Procedures, check the following:1. Standby Pressure2. Steering Relief Pressure3. Auxiliary Relief Pressure4. Implement Relief Pressure

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Boom and Frame for Damage

EQUIPMENT REQUIRED:

TelehandlerProper lighting

PROCEDURE:

Follow Service Manual Procedure

REFERENCE:

Service Manual - Operation and Maintenance Guide. Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Boom Lowering and Retracting Without Hydraulic Power.

EQUIPMENT REQUIRED:

TelehandlerProper Lifting and Lowering Equipment to handle Boom Weight

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Boom Wear Pads.

EQUIPMENT REQUIRED:

TelehandlerFeeler Gages

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Boom Chain Tension / Adjustment

EQUIPMENT REQUIRED:

Telehandler

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Setting and using the Three Different Steer Modes.

EQUIPMENT REQUIRED:

Telehandler

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Operation of Differential Lock Control.

EQUIPMENT REQUIRED:

Telehandler

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Purging Air From the Boom Extend / Retract Cylinder.

EQUIPMENT REQUIRED:

Telehandler

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Learning the Truck

EQUIPMENT REQUIRED:

Order Picker (NOR) Familyor

Reach (NRR) Family

PROCEDURE:

1. Follow Service Manual Procedure to Enter, Run, and Exit the Learn Program.

REFERENCE:





REVISED 2001



TITLE: Demonstrate a Voltage Test on the Power Supply Card in the Vehicle Manager.

EQUIPMENT REQUIRED:


Reach (NRR) Family

PROCEDURE:

Follow Service Manual Procedure.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Testing Q1.

EQUIPMENT REQUIRED:


Reach (NRR) Family

VOM

PROCEDURE:

1. Follow Service Manual Procedure to test Q1.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Testing TM1 / TM2.

EQUIPMENT REQUIRED:

Reach (NRR) Family

PROCEDURE:

Follow Service Manual Procedure to test TM1 / TM2 on Field Wiring Board.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using Password to obtain the Truck Software (Firmware) Version.

EQUIPMENT REQUIRED:


Reach (NRR) Family

PROCEDURE:

1. Follow Service Manual Procedure.

REFERENCE:





REVISED 2001



TITLE: Demonstrate obtaining Hour Meter readings and Distance Traveled.

EQUIPMENT REQUIRED:


Reach (NRR) Family

PROCEDURE:

1. Follow Service Manual Procedure to obtain readings:1. (KH) - Key Hours2. (HD) - Hours on Deadman3. (HL) - Hours on Lift Motor4. (TM) - Travel Miles

Note: Early model trucks will not have all of the above options.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Configuring the truck using Password and Superword.

EQUIPMENT REQUIRED:


Reach (NRR) Family

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Configure Mode using Password and note all Menu Options.2. Enter the Configure Mode using Superword and note all Menu Options.3. Note the differences between the two Menus and exit the Program.

Note: Do not change any Option Values unless you are actually Configuring the Truck or note the values before changing them to re-set back to original values.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Configuring the Truck to Factory Default Setting Values.

EQUIPMENT REQUIRED:


Reach (NRR) Family

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Configure Mode using Password.2. Note all Option Values3. Default truck to Factory Setting Option Values4. Note all Option Setting Values again, if different than original change to original Values (unless you are configuring the truck differently) and exit the program.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using the Maintenance Program

EQUIPMENT REQUIRED:


Reach (NRR) Family

VOM9 & 25 Position Pin Adapters, (obtain from MHA)26-266 & 26-1945 Gender Changers, (obtain from Radio Shack)Proper Terminals

PROCEDURE:

Follow Service Manual Procedures to enter into the Maintenance Program and do:1. 3 Analog Test2. 3 Input Test3. 3 Output Test

Note: a. Read and understand the entire procedure before doing each testb. Choose test that are different in nature, (for instance in the Reach Truck Test O00, O01, O02, and O03 test contactors. Choose only one and than choose one of eight Solenoid Test, etc.)

REFERENCE:Service ManualCheck S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Initializing truck to Factory Default Parameters.

EQUIPMENT REQUIRED:

Order Picker (NOR) Family or Reach (NRR) FamilyMHA Hand Set or Laptop with proper Software Program.

PROCEDURE:

Follow SENB8544-01 (or latest version) User's Manual procedure to resetting the Vehicle Manager to Factory Default Parameters.

Note: This same Equipment and Similar Procedures are used to add or delete some Options. MHA must be contacted to obtain authorization number called a Pass Key. Once the hardware for the option is installed, this Configuration Program must be executed for the truck accept or delete the option.

REFERENCE:

Service ManualSENB8544-01 (or latest version) User's Manual





REVISED 2001



TITLE: Demonstrate the use of LED Status Light

EQUIPMENT REQUIRED:

NPP40 or Pallet Jack with similar Controller.

PROCEDURE:

Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.2.. Raise controller cover and view Status LED3. Simulate and SRO Condition.

Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE TRUCK DRIVE WHEEL UP IN THE AIR. Damage to the controller or drive motor may occur. Use the mechanical brakes to slow down and stop the drive wheel.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to Program the truck.

EQUIPMENT REQUIRED:

NPP40 or Pallet Jack with similar Controller.113-7132 Curtis 1207 Analyzer

PROCEDURE:

Follow Service Manual Procedure to:. 1. Install the Analyzer.

2. Drive the truck forward and reverse.3. Enter the Program Mode and note the Quick Start Option Value.4. Change it to its minimum Value and drive the truck forward and reverse.5. Change it to its Maximum Value and drive the truck forward and reverse. (truck TAKE OFF SPEED will be faster, make sure you have enough room to perform this test properly)6. Note the difference and change it back to its original Value.

Note: Look at other options, note there value if you change it, and set it back to Its original value, unless you are configuring the truck differently.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to Test the truck.

EQUIPMENT REQUIRED:


PROCEDURE:

Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.

. 2. Install the Analyzer.3. Enter the Test Mode4. Look at all Test Options. Operate the truck while viewing test results.

Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE TRUCK DRIVE WHEEL UP IN THE AIR. Damage to the controller or drive motor

May occur. Use the mechanical brakes to slow down and stop the drive wheel.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using the 113-7132 Curtis 1207 Analyzer to enter Diagnostics and Special Diagnostics Menu.

EQUIPMENT REQUIRED:


PROCEDURE:

Follow Service Manual Procedure to:1. Raise and block truck so drive wheel is free to turn.

. 2. Install the Analyzer.3. Enter the Test Diagnostic mode, ( This is not a menu as such, but simply a list of possible messages you may see displayed when the programmer is operating in either Program or Test Mode), note any faults and exit program.

Note: DO NOT PLUG (ELECTRICAL BRAKING & REVERSING) THE TRUCK DRIVE WHEEL UP IN THE AIR. Damage to the controller or drive motor

May occur. Use the mechanical brakes to slow down and stop the drive wheel.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using Programmable Setup Options.

EQUIPMENT REQUIRED:

EC15 - EC30EP13T - EP20TM40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Setup Option Program.2. Note all Option Values3. Default truck to Factory Setting Option Values4. Note all Option Setting Values again, if different than original change to original Values (unless you are configuring the truck differently) and exit the program. After finishing put the Run, Diagnostic (Setup) Switch back to Run.

Note: If using the EC15 - EC30 W / MicroCommand II Panel, make sure to to access all three option groups.

REFERENCE:

Service ManualSales Monitor CEKL0367 (for M50SA & P family of trucks)





REVISED 2001



TITLE: Demonstrate using the Diagnostic Program

EQUIPMENT REQUIRED:

Any Electric Lift Truck, (Caterpillar or MCF) with MicroCommand Panel

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Diagnostic Program2. Note all Faults, (if none exit the Program)3. If faults are found make proper repairs

Note: It’s a good Idea to record the Fault Codes and Hrs. (if applicable)in the Service Report before erasing the Fault Codes and Hrs.After finishing put the Run, Diagnostic (Setup) Switch back to Run.

REFERENCE:





REVISED 2001



TITLE: Demonstrate using the History Folder Faults

EQUIPMENT REQUIRED:

EC15 - EC30EP13T - EP20TM40DDSA / P - MC60DSA / P W / 0R6713 Programmable Logic.

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Fault History Program.2. Note all Faults, (if none exit the Program)3. If faults are found make proper repairs

Note: It’s a good Idea to record the Fault Codes and Hrs. (if applicable)in the Service Report before erasing the Fault Codes and Hrs.After finishing put the Run, Diagnostic (Setup) Switch back to Run.

REFERENCE:

Service ManualSales Monitor CEKL0367 (for M50SA & P family of trucks)





REVISED 2001



TITLE: Demonstrate Programming the Clock on a EC15 or EC30 Lift Truck

EQUIPMENT REQUIRED:

EC15 - EC30

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Program.2. Change time using the 24 hour clock instead of the 12 hour clock.3. Using the 24 hour clock, change the time back to correct time, and back to 12 hour clock, (if the truck is programmed for the 24 hour clock leave it at the 24 hour clock).

REFERENCE:





REVISED 2001



TITLE: Demonstrate using Function Setup Procedures.

EQUIPMENT REQUIRED:

Any Electric Lift Truck W / EV100 LX, LXT, or ZX Panel97124-07400 EV100 LX Handset

PROCEDURE:

Follow Service Manual Procedure to:1. Enter the Function Setup Program2. Note all Function Values3. Check against Manufacturer recommended values.4. Make necessary changes and exit program

REFERENCE:





REVISED 2001



TITLE: Demonstrate Down Loaning Faults on a Machine using the Scroll and Clear Switches

EQUIPMENT REQUIRED:

Machine With an Electronic Control 4C8195 Caterpillar Service Tool

PROCEDURE:

1. Using the Service and Set Switches on the machine ,or Caterpillar Service tool 4C8195 enter the fault code mode and scroll through and record the fault codes

REFERENCE:





REVISED 2001



TITLE: Demonstrate Bench Testing a Hydraulic Cylinder

EQUIPMENT REQUIRED: Hydraulic Cylinder Test Bench

PROCEDURE: 1. Properly Mount Cylinder to Test Bench, Test Cylinder for Internal and

External Leakage

REFERENCE:





REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of a Planetary Final Drive

EQUIPMENT REQUIRED:

Planetary Final Drive Lifting Equipment

PROCEDURE:

1. Follow Procedure Outlined in the Applicable Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of a Differential

EQUIPMENT REQUIRED:

DifferentialDial Indicator GroupHand Tools

PROCEDURE:

1. Using the Procedure Outlined in the Service Manual Correctly Disassemble and Assemble a Differential Making All Preload and Bearing Adjustments. Correctly Set Pinion Depth, Gear Backlash and Tooth Pattern

REFERENCE:





REVISED 2001



TITLE: Demonstrate Correct Disassembly and Assembly of a CountershaftTransmission

EQUIPMENT REQUIRED:

Countershaft TransmissionHand Tools

PROCEDURE:

1. Using the Procedure Outlined in the Service Manual Correctly Disassemble and Assemble the Transmission making All Bearing Prelaod and Clearance Adjustments

REFERENCE:





REVISED 2001



TITLE: Demonstrate Setting Transmission Transfer Gear the Bearing Clearance

EQUIPMENT REQUIRED:

Transmission Transfer GearDial Indicator GroupHand Tools

PROCEDURE:

1. During Assemble of the Transmission Transfer Gear Group Correctly Set all Bearing Clearances.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Disassembly and Assembly of an Integral Axle

EQUIPMENT REQUIRED:

Integral Type AxleDial IndicatorHand Tools

PROCEDURE:

1. Disassemble and Assemble Axle as Outlined in the Service Manual Correctly Make all Preload and Clearance Adjustments

REFERENCE:





REVISED 2001



TITLE: Demonstrate Bench Testing a Countershaft Transmission

EQUIPMENT REQUIRED:

Transmission Test BenchCountershaft TransmissionHand Tools

PROCEDURE:

1. Test and Adjust the Transmission as Outlined in the Service Manual Transmission Testing and Adjusting Section

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of the 9U7500 Transmission Analyzer

EQUIPMENT REQUIRED:

9U7500 Transmission AnalyzerMachine with ICM Transmissionor ICM Transmission on the Test Bench

PROCEDURE:

Following the Instructions Outlined in the 9U7500 TransmissionAnalyzer Operation Manual1. Connect Analyzer to the Transmission using the Correct Cables2. Test the Transmission Switch3. Test the Solenoids 4. Shift the Transmission

REFERENCE:

Service ManualTransmission Analyzer Operation Manual NEHS0644





REVISED 2001



TITLE: Demonstrate Checking Phase Rotation of a Generator Set to Utility Power

EQUIPMENT REQUIRED:

Generator Set Connected to Utility Power Phase Rotation Meter Safety Equipment

PROCEDURE:

1. Follow Instructions Outlined in the Service Manual





REVISED 2001



TITLE: Demonstrate Proper Work Area Organization

EQUIPMENT REQUIRED:

None

PROCEDURE:

1. Organize work area as per instructions from a senior technician or supervisor

REFERENCE:

None Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Performing the Five Steps of Engine Troubleshooting

EQUIPMENT REQUIRED:

Truck Engine with Electronic ControlsApplicable Test Equipment

PROCEDURE:

Troubleshoot the Engine using the Five Step Diagnostic ProcessOutlined in the Service Manual1. Gather Information2. Verify Operational Problem3. Determine Probable Causes4. Narrow List of Causes5. Test Subsystems

REFERENCE:

Service ManualElectronic Troubleshooting SENR5582





REVISED 2001



TITLE: Instruct Junior Technicians in Work Area Organization Who Need Skill 454

EQUIPMENT REQUIRED:

None

PROCEDURE:

REFERENCE:

Skill # 454 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Removal And Installation Of A Tapered Roller Bearing

EQUIPMENT REQUIRED

Component With Tapered Roller Bearings Bearing Removal And Installation PullersBearing HeaterHand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking Track Adjuster for Leakage (Internal and External)

EQUIPMENT REQUIRED:

Roller Frame with track adjuster Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Evaluation of a Dozer Blade for Wear

EQUIPMENT REQUIRED:

Dozer Blade Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Evaluation of Loader Frame and Linkage for Wear

EQUIPMENT REQUIRED:

Loader Frame Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Boring Idler Bearings on High Sprocket Machines

EQUIPMENT REQUIRED:

Idler With New Bearings Boring Bar Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Evaluation of Pivot Shaft for Leakage and Wear

EQUIPMENT REQUIRED:

Large Track Type Tractor With Pivot Shaft Lifting and Blocking Equipment Dial Indiactors Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Field Repair Procedure for a Dry Joint on S.A.L.T. Track

EQUIPMENT REQUIRED:

Machine with S.A.L.T. track Portable track Press Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Lubrication of a Pivot Shaft

EQUIPMENT REQUIRED:

Large track type tractor with a Pivot Shaft Hand Tools

PROCEDURE:

Follow Procedure Outlined In The Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Pivot Shaft Seal Installation

EQUIPMENT REQUIRED:

High drive Track Type Tractor With Pivot Shaft Seal Installation Tooling Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Evaluation of Equalizer Bar For Wear

EQUIPMENT REQUIRED:

Equalizer Bar or Track Type Tractor With Equalizer Bar Measuring Tools Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Properly Checking Roller Frame Alignment

EQUIPMENT REQUIRED:

Measuring Tools Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Removal and Installation of a Recoil Spring on Low Sprocket Machine

EQUIPMENT REQUIRED:

Low Sprocket Machine Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual (making sure to follow all safety precautions)

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Removal and Installation of Recoil Spring on High Sprocket Machine

EQUIPMENT REQUIRED:

Track Type Tractor With High Drive Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual (Making sure to follow all prescribed safety precautions)

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Disassembly and Assembly of Low Sprocket Recoil Spring

EQUIPMENT REQUIRED:

Recoil Spring Assembly From A Low Sprocket Machine Recoil Spring Press Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual (making sure to follow all safety precautions outlined)

REFERENCE:





REVISED 2001



TITLE: Demonstrate Manuel Operation of a SGV (Self Guided Vehicle)

EQUIPMENT REQUIRED:

SGV Truck With Pendant Controller Hand Tools

PROCEDURE:

1. Install Pendant and Basic Maneuver Vehicle. 2. Follow Procedure Outlined In The Service Manual

REFERENCE:

SGV Service Manuel Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate SGC Basic Computer Skills With Lap Top Computer

EQUIPMENT REQUIRED:

P.C. with Windows GEM 80 Software Hand Tools

PROCEDURE:

1. Access GEM 80 Program 2. Download file to SGV 3. K-400 Procedure


REFERENCE:

SGV Service ManuelGEM 8 Software Tools and Utilities Book





REVISED 2001



TITLE: Demonstrate Land Base Computer Skill Test

EQUIPMENT REQUIRED:

SGV Land Base Computer Hand Tools

PROCEDURE:

1. Download Target Files to SGV 2. Look at Location Control 3. Look at Alarm History Files


REFERENCE:LCS User Guide for SGV





REVISED 2001



TITLE: Demonstrate Test/Adjustment of Photo Electric Sensor

EQUIPMENT REQUIRED:

Volt Meter Hand Tools

PROCEDURE:

1. Test for Voltage and Visual Alignment Follow Procedure Outlined In The Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate I/O Panel wiring on Landbase Computer for SGV

EQUIPMENT REQUIRED:

Prints of System Wiring Hand Tools

PROCEDURE:

1. Trace Wires from Battery Charger to Panel


REFERENCE:

Plant Wiring Schematic Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully Complete Interactive Computer Course, Fundamentals Of Electrical Systems

EQUIPMENT REQUIRED:

Computer with Caterpillar Interactive Software Program, Fundamentals Of Electrical Systems (TEMV9002)

PROCEDURE:

1. Follow Computer On Screen Directions And Complete The Entire Course

REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Computer Course, Fundamentals Of Mobile Hydraulics

EQUIPMENT REQUIRED:

Computer with Caterpillar Interactive Software Program, Fundamentals Of Mobile Hydraulics (TEMV9001)

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully Complete Interactive Computer Course, Fundamentals Of Applied Failure Analysis

EQUIPMENT REQUIRED:

Computer with Caterpillar Interactive Software Program, Fundamentals Of Applied Failure Analysis

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Use Of The Roto Alignment Tool

EQUIPMENT REQUIRED:

Roto Alignment Tool Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of S.I.S. (Service Information System)

EQUIPMENT REQUIRED:.Computer that has S.I.S. installed

PROCEDURE: Write your answer at the end of each question.1. Find the torque for the bolt that holds the crankshaft hub and the damper

on a D7H serial number 82Z12987. 2. Find the description for a 3P5715 located in the final drive of a D7F serial

number 93N01175.3. Find the part number for the tip at the end of the ripper shank for a D7H

serial number 4AB05501.4. Find the tooling necessary to remove and install the valve seat inserts in a

D7H 79Z04001.5. Find the new replacement part number for the 1115152 powertrain oil

hose on a D5M S/N 6AS425 listed in Service Letter – May 31,1999.6. Find the new part number for the sprocket segments on a D7H serial

number 4AB05501.7. Find the part number for the “Extreme Service” cab door striker listed in

Special Instruction on a D11N, S/N 74Z.8. Find the nominal low idle speed for an engine in a D7H serial number

79Z05636 equipped with an engine serial number 08Z75146.

REFERENCE:REBW0005- S.I.S. (Service Information System) User ProceduresCheck S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Identifying Air Conditioning System Type

EQUIPMENT REQUIRED:

Air condition equipped equipment.

PROCEDURE:

EXAMINE AIR CONDITIONING SYSTEM, LOOKING AT THE SERVICE FITTINGS AND IDENTIFICATION PLATES AND DETERMINE TYPE OF REFRIGERANT USED (R-12, R134a) Follow Procedure Outlined In The Service Manual





REVISED 2001



TITLE: Demonstrate Testing An Adjustable And None Adjustable Thermostatic Switch

EQUIPMENT REQUIRED:

Machine With Air Conditioning Multimeter Heat Source Cold Source Thermometer Hand Tools

PROCEDURE:


REFERENCE:

Service Manual - SENR5664 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Performance Testing Heating System

EQUIPMENT REQUIRED:

Machine With Heating And Air Conditioning System Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Flushing An Air Conditioning System That Has Had A Component Failure

EQUIPMENT REQUIRED:

Recovery & Recycle Cart R134a Refrigerant Supply 153-8538 Flushing Solvent Flushing Tool Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Down Loading Faults And Error Codes On An Automatic Temperature Control Air Conditioning Unit

EQUIPMENT REQUIRED:

Machine With Automatic Temperature Control Air Conditioning Hand Tools

PROCEDURE:


REFERENCE:

Service Manual - RENR1976 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Timing New Components To An Automatic Temperature Control Air Conditioning Unit

EQUIPMENT REQUIRED:

Machine With Automatic Temperature Control Air Conditioning Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Reading Component Parameters On An Automatic Temperature Control Air Conditioning Unit

EQUIPMENT REQUIRED:

Machine With An Automatic Temperature Control Air Conditioning Unit Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual 2. Fill Out Worksheet #38 And Attach It To This Form

REFERENCE:





REVISED 2001



TITLE: Demonstrate “Quick-Check” Procedures For Expansion Valve Or Orifice Tube Air Conditioning

EQUIPMENT REQUIRED:

Machine With Air Conditioning HAND TOOLS

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Performance Testing An Air Conditioning System

EQUIPMENT REQUIRED:

Machine With Air Conditioning Thermometer Manifold Gauges Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual record your findings on Worksheet 39 and attach to this form

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Method Of Finding Restrictions In An Air Conditioning System

EQUIPMENT REQUIRED:

Machine With Air Conditioning System Manifold Gauges Thermometer Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking The Oil Level In An Air Conditioning Compressor

EQUIPMENT REQUIRED:

Machine With An Air Conditioning System Recovery/Recycle Equipment Measuring Container Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Removal And Installation Of An Air Conditioning System Orifice Tube

EQUIPMENT REQUIRED:

Machine With Orifice Tube Type Air Conditioning System 1U9890 Orifice Tube Extraction And Installation Tool Recovery/Recycle Equipment Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Use Of Air Conditioning Electronic Charging Scale

EQUIPMENT REQUIRED:

9U6507 Electronic Charging Scale Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Method Of Checking Cab Sealing

EQUIPMENT REQUIRED:

Machine With Air Conditioning And/or Heating 4C5623 Smoke Candles Hand Tools

PROCEDURE:

1. Place Candle On A Non Flammable Disposable Material In The Center Of The Cab Floor. Follow Procedure Outlined In The Service Manual

REFERENCE:

Tool Guide Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Method Of Testing A Thermostatic Expansion Valve With The Valve Installed On The Machine

EQUIPMENT REQUIRED:

Machine With Thermostatic Expansion Valve Type Air Conditioning Manifold Gauges 9U6070 Heat Gun (Or Source Of Alternate Heat) Ice Or Alternate Source Of Cold (Do Not Use Refrigerant) Hand Tools

PROCEDURE:

1. Install Manifold Gauges, Apply Cold Source To TXV And Read Gauges. 2. Apply Heat Sources To TXV And Read Gauges 3. Follow Procedure Outlined In The Service Manual 4. Record Findings On Worksheet # 40 And Attach To This Form

REFERENCE:





REVISED 2001



TITLE: Demonstrate Checking And Setting Clutch Clearance (Dry Plate) On Standan Compressor

EQUIPMENT REQUIRED:

Standan Compressor Feeler Gauges “T” Puller Hand Tools

PROCEDURE:


REFERENCE:

Service Manual - SENR5664 SEBU2580 (Service Training Meeting Guide)





REVISED 2001



TITLE: Demonstrate Leak Testing Air Conditioning System

EQUIPMENT REQUIRED:

Machine With Air Conditioning 4C2964 Electronic Leak Detector (Or Equivalent) Air Conditioning Dye Soap Solution in Squirt Bottle Hand Tools

PROCEDURE:

1. Leak Test Air Conditioning System Using The Different Methods Of Detection. Follow Procedure Outlined In The Service Manual

REFERENCE:





REVISED 2001



TITLE: Demonstrate Retrofitting An R-12 Air Conditioning System To R134a

EQUIPMENT REQUIRED:

Machine Equipped With An R-12 Air Conditioner Recovery/Recycle Equipment Hand Tools

PROCEDURE:

1. Follow Procedure Outlined In The Service Manual And Special Instructions

REFERENCE:





REVISED 2001



TITLE: Demonstrate Use of Electronic Technician (ET) on a Unit with Electronic Control

EQUIPMENT REQUIRED:

Lap Top Computer with ET Installed Unit With an Electronic Control That Required ET Communication adapter with cables. Hand Tools

PROCEDURE:

1. Connect Computer with ET Using Communication Adapter with Appropriate cables to Unit According to Service Manual

2. View the Active and Logged Codes With Caterpillar ET (Electronic Technician) Follow Procedure Outlined In the Service Manual

3. Attach A Paper Copy of the Active Codes, or Logged Codes, or Configuration of Unit with the this Skill Sheet.

REFERENCE:

Training Package inside ET software (Must have ET open before you can Access Training Package) Book on Introduction to Microsoft Windows operating System Service Manual Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Installation Of Generator Protection Components

EQUIPMENT REQUIRED:

Generator; Protection Components

Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Installation of Generator AC Monitoring Components

EQUIPMENT REQUIRED:

Generator AC Monitoring Components Generator Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Modification Of Engine Generator Controls As Directed

EQUIPMENT REQUIRED:

Engine And Generator Set Hand Tools

PROCEDURE:

Follow Procedure Outlined In The Service Manual As Directed

REFERENCE:





REVISED 2001



TITLE: Demonstrate Performance Of A Cooling System Audit

EQUIPMENT REQUIRED:

Engine With A Radiator Type Cooling System Cooling System Audit Equipment Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Performing Tests Listed On 3500 Engine Installation Check List

EQUIPMENT REQUIRED:

3500 Engine Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Demonstrate Performing Generator/ Industrial Engine Load Test And Determine Compliance With Performance Standard

EQUIPMENT REQUIRED:

Engine Generator Set Hand Tools

PROCEDURE:


REFERENCE:





REVISED 2001



TITLE: Successfully complete Programs in Learning Operating Techniques. An Introduction to Compression

EQUIPMENT REQUIRED:

Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1051WB “An Introduction to Compression”

PROCEDURE:

Study material and take test, score at least 80%

REFERENCE:

Introduction to Compression Book # 1051WB Howell Training - Houston, Texas (800) 527-1851 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully complete Programs in Learning Operating Techniques. Couplings, Gear Trains, and V-Belt Drives

EQUIPMENT REQUIRED:

Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1085WB “Couplings, Gear Trains and V-Belt Drives”

PROCEDURE:


REFERENCE:

Coupling, Gear Trains and V-Belt Drives Book #1085WB Howell Training - Houston, Texas (800) 527-1851 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully complete Programs in Learning Operating Techniques. Centrifugal Compressors

EQUIPMENT REQUIRED:

Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1053WB “Centrifugal Compressors”

PROCEDURE:


REFERENCE:

Centrifugal Compressors Book #1053WB Howell Training - Houston, Texas (800) 527-1851 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Successfully complete Programs in Learning Operating Techniques. Positive Displacement Compressors

EQUIPMENT REQUIRED:

Pencil and paper Booklet - American Petroleum Institute Programs In Learning Operating Techniques #1052WB “Positive Displacement Compressors”

PROCEDURE:


REFERENCE:

Positive Displacement Compressors Book #1052WB Howell Training - Houston, Texas (800) 527-1851 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Proper Preventative Maintenance and Inspection of a Gas Compression Unit

EQUIPMENT REQUIRED:

Gas Compression Unit

PROCEDURE:

1. Follow procedure outlined in the appropriate service manual. Record your findings on worksheet # 41 and attach to this form.

REFERENCE:

Service Manual Operation and Maintenance Manual for Caterpillar Gas Engine (Lubricant Recommendations SEBU6400) Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 7X1400 Gas Engine Digital Diagnostic Tool (DDT) Group

EQUIPMENT REQUIRED:

Electronic Controlled Gas Engine 7X1400 Gas Engine Digital Diagnostic Tool

PROCEDURE:

Follow procedure outlined in the appropriate service manual.

REFERENCE:

Service Manual Operating Manual SEHS9122 Operating Manual SEHS8806 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Use of the 4C5850 Stud Tensioner Tool Group

EQUIPMENT REQUIRED:

4C5850 Stud Tensioner Tool Group 3S6224 Electric Hydraulic Pump 8T0820 Hydraulic Pressure Gauge 8T3035 Hydraulic Line

PROCEDURE:

Follow procedure outlined in the appropriate 3600 series service manual.

REFERENCE:

3600 Series Engine Service Manual Special Instruction SEHS9156 Check S.I.S. or S.I.R.S. and FIND for the latest updates




REVISED 2001



TITLE: Demonstrate Checking Engine/Compressor Soft Foot

EQUIPMENT REQUIRED:

Dial Indicator Group Mounting Feet Shims (As required by each Manufacture)

PROCEDURE:

Follow Procedure Outlined in the Appropriate Manufactures Service Manual.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Starting and Stopping of a Gas Compressor Package

EQUIPMENT REQUIRED:

In-service Gas Compression Package

PROCEDURE:

Follow Procedure in American Institute Programs in Learning Operating Techniques #1052WB “Positive Displacement Compressors” Section 3

REFERENCE:

Positive Displacement Compressors Book #1052WB (Howell Training - Houston, Texas (800) 527-1851) Check the S.I.R.S. and FIND for latest updates




REVISED 2001



TITLE: Demonstrate Proper Checking Method for Crosshead Clearance

EQUIPMENT REQUIRED:

12 inch Long Feeler Gauges

PROCEDURE:

1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Proper Checking Method for Rod Run Out.

EQUIPMENT REQUIRED:

Two Dial Indicator Groups

PROCEDURE:

1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual to ensure Rod Run Out is within Manufacturers’ Specifications.

REFERENCE:





REVISED 2001



TITLE: Demonstrate Purging Gas From Unit

EQUIPMENT REQUIRED:

In-service Gas Compression Package.

PROCEDURE:

1. Follow Procedure Outlined in the Appropriate Manufactures Service Manual.

REFERENCE:





REVISED 2001

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